Zone 1

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • The water baths are free of calcium / salt / hard water build up

Zone 2

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 3

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 4

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 5

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 6

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Locations of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 7

  • Zone 7

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 8

  • Zone 8

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The tops of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 9

  • Zone 9

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The top of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 10

  • Zone 10

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The top of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / hard water build up

Zone 11

  • Zone 11

  • Sort

  • Obsolete / Unused items have been removed

  • Scrap wood / conduit / misc. items have been picked up

  • Loose hardware is in the magnetic trays

  • Anti seize, oil cans, copper tape, spray paint cans have been removed

  • The top of cabinets / hardware bins and walkways are clear

  • Set in Order

  • Location of hand tools is clear

  • Location of spare equipment is clearly identifiable

  • There are an adequate number of cleaning stations available

  • Location of heat gloves is visible

  • Spare parts are organized in cabinets or on shelves

  • Shine

  • Floor has been swept - no resin, floor dry or excessive amount of dirt

  • Cool purging's have been picked up in an appropriate time

  • The equipment is free of dirt and grime build up

  • There are no oil leaks on the equipment

  • Water baths are free of calcium / salt / had water build up

Red Tag Zone

  • Sort - Have items been dispositioned within 1 month

  • Set in Order - Red tags are available, Items are stored in an Organized fashion

  • Shine - The area is clean (free of oils spills, dirt, loose pallets, etc.)

  • Standardize - All items have a red tag attached and it's filled out completely

  • Sustain - Red tag zone procedure is displayed

Standardize

  • Where is the plant at with Standardize

  • Shadow foam / boards , visual controls have been created for hand tools and cleaning stations

  • Location of items is visual, color coding is being used

  • Kanban is being used

  • SOP's are being displayed

  • Cleaning stations have a consistent layout

Sustain

  • How is the plant doing at sustaining the improvements that have been made

  • All hand tools / brooms / cleaning tools are in their place

  • Spare / Extra equipment is in it's place

  • Kanban items are being replenished in an appropriate time

  • 5S / Improvement leaders have been identified

  • Monthly 5S audits are being performed and documented

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