citra tubindo

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5S PRACTICE MANUAL(LEAN MANAGEMENT WITH 5S TECHNIQUE)


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PT. CITRA TUBINDO TBK.

5S PRACTICE MANUAL

(LEAN MANAGEMENT WITH 5S TECHNIQUE)

PT. Citra Tubindo, Tbk., Hang Kesturi Street KM 4 Kabil, (62) 778 711 888


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By:

5S Team of PT. Citra Tubindo Tbk.

Layout (Setting):Susanti, SS(a.k.a Susan)

Advisor :Andi Tanuwidjaja

First Edition, 22 June 2014

Printed for own circle

PT. Citra Tubindo, Tbk, Hang Kesturi Street KM 4 Kabil, (62) 778 711 888


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Department _____________________________

Bookplate _____________________________

Title _____________________________

Employee No. _____________________________

PT. Citra Tubindo, Tbk, Hang Kesturi Street KM 4 Kabil, (62) 778 711 888


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The Author Dedication

The authors dedicate this book to the PT. Tubindo Citra Tbk, with particular

thanks to the 5S God Father ( Mr. Eric Atton ) which ever mentions the word "

5S " the first time to the author when newly joined the company two and a half

years ago.

To Mr. Andi Tanuwidjaja are entrusted to the author to continue the journey in

the company's 5S program. The entire 5S Area Leader, Sub Area Leader,Zone , Auditor and all employees who participate, support and strive to

succeed in this program.

Finally, the partner of author Mark P. Hubbard as tutors and personal trainers

author who has been sharing experiences and valuable knowledge to the

author when developing its work during the process of implementing a 5S

program is underway at the company.


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TABLE OF CONTENTS

TABLE OF CONTENTS

PREFACE

THE STRUCTURE OF WHEEL COMMITTEE

COMPANY HISTORY

MANAGEMENT COMMITMENT PT. TUBINDO CITRA Tbk.

CHAPTER I. INTRODUCTION

A. History of 5S Concept

B. The Definition of 5S

C. Why need 5S

D. The Purpose of 5S application

E. The Advantage of 5S application

F. The Objective of 5S application

G. The Benefit of 5S application

CHAPTER II. APPLICATION AND KEY SUCCESS OF

5S APPLICATION

How is the application of 5S

Key Success of 5S application

The Impact of the 5S application

CHAPTER III. AUDIT OF 5S


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CHAPTER IV. BOOSTER FACTOR AND IMPLEMENTATION OF 5S

OR 5R

A. The Booster Factor

A.1 The Management Commitment

A.2 Organization

A.3 Training and Promotion

B. Implementation of 5S/5R

B.1 S1 (Seiri)

B.2 S2 (Seiton)

B.3 S3 (Seiso)

B.4 S4 (Seiketsu)

B.5 S5 (Shitsuke)

CHAPTER V. 6S (5S + 1S SAFETY)

CHAPTER VI. CLOSING


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PREFACE

This book is the result of passion and hard work of the team 5S, ie. all

employees at PT. Tubindo Citra Tbk. in the application of the 5S concept in

the workplace. This book also as the proven commitment of all employees of

PT. Citra Tubindo Tbk., to make the Company as the World Class

Manufacturing that achieving the standardization level of clean, healthy and

save of working area.

Cleanliness arise from a pure soul, able to produce thoughts, behavior,

atmosper environment which will delivered to a life that is clean, clear,

beautiful and peaceful in every way. The life as it is desired by the faithful .

-------------------------- @ @ --------------------------

Name : Susanti (a.k.a. Susan)

Title : 5S Coordinator (Authors)

-------------------------- @ @ --------------------------


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5S program has been implemented in Citra Tubindo since 2011, but the

dissemination and promotion of the 5S program not complete communicated

to all employees in the company. Lack of awareness of the 5S program that is

the foundation of discipline and moral patterns of employees to work in the

work environment, resulted in the adoption and implementation of 5S

becomes less good and less effective, thus there arose a wide range of waste

going on in the company.

In 2013, 5S program returned intensively done by way of training, both theory

and practice as well as promotion to all employees from superiors to

subordinates without exception, the implementation of the patrol, weekly

meetings, regular evaluation of the implementation of 5S to involve the

employees themselves, learn discipline, communicate well and lead members

in each department of the 5S projects, provision of support facilities, as well

as 5S competition, was able to make all employees of PT. Tubindo Citra Tbk.

aware of the importance of the working environment which is clean, beautiful,

healthy and safe, in order to smooth productivity, happiness and comforttogether while working at the company.

With proud of this year PT.Tubindo Citra Tbk. has become a pilot (

Benchmark ) by the company Vallourec shareholders of some countries, such

as Singapore, France, Saudi Arabia, UK, etc. As well as the company's main

Petromas Hymindo for the implementation and execution of one of the

concepts of lean management with basic techniques 5S.

Although the implementation of 5S in PT. Tubindo Citra Tbk was not perfect,

but the author believes that continuous improvement is constantly being

made and upgraded as possible during this sturdy stand firm in Indonesia

beloved motherland.


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-------------------------- @ @ --------------------------

Name : Andi Tanuwidjaja

Title : Operation Director (Advisor)

-------------------------- @ @ --------------------------

In order to participate in global competition and competes against numerous

competitors locally and globally, PT Citra Tubindo Tbk is continuously looking

to find ways to reduce cost, improve quality and delivery time. For this reason,

PT Citra Tubindo Tbk is implementing lean manufacturing, which allows

improvements in processes while increasing the quality of the products.

5S is one of the most fundamental of lean manufacturing. Its application is

simple, however, the advantages are endless.

One of the great aspects of implementing 5S is that everyone can participate

and its use is not limited to production area but office can also achieve

productivity gains from implementation of 5S.

The following is a list of most obvious benefits which can be derived from


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implementation of 5S at PT. Citra Tubindo Tbk :

Reduce lead time thereby improving delivery times

Reduce equipment downtime, maintenance and cycle time

Reduce changeover time

Reduce cost by reducing space requirement and number of scrap

Improve working condition and increase employees moral

Improve quality by reducing the amount of defects

Improve safety thereby reducing the cost of workers injuries

Improve visual communication

After years of implementation at PTCT, 5S has raised the bar to a new

standard. Continuous effort from everyone at all level, top management

commitment, and follow up procedure to maintain are the key components for

maintaining the level of excellence.


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COMPANY HISTORY

PT. Tubindo Citra Tbk was established on August 23, 1983 in the context of

Domestic Investment ( DCI ) and the legal domicile in Batam, Indonesia.

Company's Head Office and factory located in Jl. Hang Musk I, Kav.C1, Kabil

Industrial Estate, Batam, Indonesia.

PT. Tubindo Citra Tbk is engaged in trade and industry, providing services in

the field of oil and gas industry and mining. To achieve its goals and

objectives the company carries out business activities such as create, provide

service, repair tools and equipment to support the oil and gas industry. The

company's vision as a company that produces World Class Oil Country

Tubular Goods ( OCTG ), maximizing profits Shareholders and improve

people's lives. The mission of the company to be able to grow and compete

on an ongoing basis achieving superior operational performance, able to

meet customer needs in terms of price, quality and timeliness of delivery,

innovate and invest in research and development ( R&D ), maximizingshareholder profits, exporting world-class products.

- Preserving the Environment Being a leader in environmental issues and

prevent any kind of pollution, conserve water and neutralize waste

- Using technology that is clean and safe

- Reducing carbon emissions and waste disposal

- Using energy-efficient

The company operated its activities in accordance with the goals and

objectives set forth in the Articles of Association of the Company, namely as

the suppliers of " Oil Country Tubular Goods " ( OCTG ), pipes and drill pipes

for oil and gas companies, which include seamless pipe with "


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AmericanPetroleum Institute " API and Premium Connection, seamless pipe

and seamless pipe drilling.

Fields and Business Company activities :

Pipe threading and services

- Perform fabrication of various types of classes as well as connections

and pipes and accessories under the license given by the famous maker

of seamless pipes in the world including, Vallourec, NSSMC and

Tenaris.

- Performing the production of the threading protector and packing

systems for threadguard that reduce dependence on suppliers.

- Whorls manufacture of steel pipe, either with seam or without seam,

according to the standard API, in a variety of sizes from 2-3/8 " to 20 ".

- Making pipe connections ( coupling ) according to the standard API.

- Straightness testing pipes and pipe fittings and pipe whorls resistance

by using the power of certain water pressure. Manufacture of pipe

accessories, among others : " Pup Joint ", " Cross Over " and " BlastJoint ".

- Coating and plating threading pipe with phosphate, tin, copper and zinc

materials.

- Providing the inspection services, repair and cleaning of the pipe and its

threading.

- Producing various types of pipe threads and its accessories under

license from various steel pipe mill " seamless " in the world, including

leading technical assistance from : Vallourec and Nippon Steel and

Sumitomo Metal Corporation to manufacture and repair the pipe

threading and accessories type VAM and BIG OMEGA.

- Thermal Spray Aluminum (TSA) to control the corrosion in the special

pipes.


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Heat Treatment Facilities

Commercial operations since 1992 and has received a certificate of

recognition quality of the API in March 1992. Factory installed production

capacity reaches 120,000 metric tons per year for the pipes diameter

between 2-3/8 " to 13-3/8" according to the standard American Petroleum

Institute ( API ) and Premium Grade.

The Company Testing Facilities has a reliable testing facility and calibrated

to ensure the quality of products produced, that is :

a. Destructive Testing

Pull test : to find out the strength of ductile and pull a product with its

flexibility.

Spectrometer test : to measure the metals content to suit the needs of

consumers.

Hardness test : to ensure that the hardness of the product remains in

force tolerance given in the final product.Flexibility test : to test the flexibility of the pipe at room temperature or

in freezing temperatures.

Metallurgical test : to be able to describe the structure of the metal in

the micro and macro, so that the final product is acceptable according

the specifications of consumers.

External pressure test : to ensure that the pipe can receive a

maximum pressure from the outside in accordance with the

conditions established international standards.

b. Non Destructive Testing

Special End Area Magnetic Particle Inspection : the method of testing

conducted for the presence of defects at the ends of the pipe.


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Magnetic Particle Inspection : used to ensure the absence of defects

in the coupling.

Ultra Sonic Testing.

Electro Magnetic Testing.

Hydrostatic Testing.

Dimens Testing.

c. Production Process

The process of making the raw pipe to become finished goods through

the following steps :

Measurements and chemical analysis on the raw pipeline to ensure

the pipes are listed according to the size of its factory-certified steel.

Once it is stored in the field.

The upsetting process for the tubing pipe which has small diameter

that need the broadening at the end of the pipe so it will increase the

thickness. While for casing pipe which has the size 5 inch or more,

the outside diameter of the pipe will be adjusted in the process ofsizing mill with controlled temperature of the pipe. Then the pipe

based on the certain size, tubing and casing, through three roll

hydraulic straightener with the controlled temperature.

De-rusting process is to clean the rust in the surface of the end of

the pipe which has box tip that will be heated or threaded.

The thermal maintenance process is to change the metal chemical

composition to become austenite, the formation of hard and strong

metal, through the process of hardening or austenizing. The level of

hardness of the pipe can be arranged upon request by heating the

pipe at temperature between 5000C up to 700

0C through the

tempering process to form a pipe in accordance with the mechanical

character.


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Cooling Process by spraying large amounts of water quickly to

change the microstructure of the steel. Pipe is allowed to cool with a

controlled pattern to maintain straightness and other characteristics

needed for further processing.

Processes lab to analyze the level of strength, microstructure and

hardness levels pipe, according to the standard API and requests of

customers by :

-- Wet magnetic particle method to check the upper end of the pipe

damage;

-- Electro-magnetic inspection, optional;

-- Ultrasonic examination conducted by third parties, companies that

use machine Truescope " ultrasonic inspection ", can give results

above 100 % detection of imperfections pipe lengthwise and

sideways as well as 100 % of the thickness of the pipe. All pipes

must be processed through this section and only that can perfectly

into the next process.

Phosphate process is to give the layer (covering) in the pin pipe-tip,after the process of threading, both with the connection of API or

premium.

The Coupling was made from seamless pipe where in the part of its

pipe wall thicker than the part of body of pipe wall that will be

connected. Coupling pipe will be heated to become similar type with

the part of the pipe, then will be cut according to the size, threaded

and given given a phosphate coating or lining " electroplated ".

Installation of coupling on each pipe with prescribed procedure

depends on the type of connection whorls both premium and API.


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Weight and length measurements were recorded after the pipe is

ready for delivery , with a mark on each pipe through the recording of

" pipe tracking system " in which the verification is done by the search

parameters in accordance with a predetermined. Each pipe was given

a layer of security.

Internal and external inspection to verify that the order is correct and

ready for shipment.


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COMMITMENT

MANAGEMENT OF PT. CITRA TUBINDO Tbk.

PT. Tubindo Citra Tbk. realize the importance of creating workplace

conditions that are safe, comfortable, orderly, clean, and well maintained

consistent in its efforts to create products of high quality, increase efficiency

and savings in the process, reduce the risk of accidents, the risk of pollution

and waste, as well as raise the profile of company in the eyes of the

customer.

For that the company is determined :

1. Applying and implementing the 5S system in every area of work for all

employees of the company sphere;

2. Includes an active role of top management and all employees in order

to achieve successful implementation of 5S system in the company;

3. Including aspects of 5S in any activity that is continuously improved by

continual improvement teamand internal auditing.

The successful implementation of 5S is highly dependent on the active

participation of all parties. For that all employees are expected to increase

self-discipline and sense of responsibility to the 5S system in each work area.


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CHAPTER I

INTRODUCTION

Probably 5S was no longer strange anymore for the people who has been

working in the industry or for the people who has the education background of

industrial engineering. 5S is as the one of the important fundamental in lean

process*. By 5S, the Company gain many benefits. Without 5S, so the

advantage from the lean will less optimal. However, it does not mean you

could not implement lean asintegral part from the Lean Process, and thereby

you can increase the performance of the Company.

The 5S program as one of the effective means of enhancing the positive

habitual of the worker, because this program is effectively proven, in

reducing the production cost, shorter lead-time, high quality of output, and

reducing the accident that emerged with the existence of the better working

condition. Generally the people states that 5S of the Housekeeping (clean-upactivity) is only to be done by the servant, housewife or hygiene officer.

The general view above is not true, particularly in the Company, however, 5S

as the tool of problem solving in work place (Tool of Problem Solving). Before

start it, you may face with the various problems that confused enough. So you

can answer these questions:

Do you have ever looking for the document for several hours?

Looks for goods and never find it, then you have to buy again?

Feels does not have enough place to keep the document or goods?

Do you have wasting time to walk up and down?

You do not know whose was borrowing your document or goods?

*Lean Process is about how to eliminate many kind of WASTE (the activity which notgiven added value) along with business flow process.


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The important document mixed with other documents or material in process

mixed with the finished goods?

The responsibility toward the cleanness and tidiness in the office and plant

(workshop) is unclear?

Are you often to consider (wasting your time) because you are unwilling to

waste it so you take the conclusion to let it or move it to other area? If this is

the fact, so it is to move the new problem to other place, is not it? These

extravagance will be revealed and to be resolved by the application and

training of 5S.

Through this manual book, PT. Citra Tubindo wants to ensure that 5S will

directly influencing toward the productivity. So it is correct, if you have

convinces that this manual book as the practical manual to be used as base

application of 5S system, even in the work place, home, social environment,

and any projects being done.

5S MUST BE AS A PART OF THE JOB

Enjoy your reading


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HISTORY OF 5S CONCEPT

More than sixty (60) years ago, the program of 5S to be introduced for the

first time in Japan. After Second World-War, Japan, as the founder of Toyota,

Sakichi Toyoda, the son of Kiichiro Toyoda, and as their Chief Engineer,

Taiichi Ohno, has developed Toyota Production System (1948 and 1975).

Toyota Production System (TPS) is the philosophy that remain to regulate, to

maintain the tidiness of manufacturing facility and free of chaos that

generates the productivity and logistic in Toyota, including the interaction with

the supplier and the customer. Then in the 1995s to be introduced 5S system

by Hiroyuki Hirano as the movement of undoubtfulness to perform sorting

(seiri), ordering (seiton), cleaning (seiso), maintenance of steady condition

(seiketsu), and awareness of the habitual to be needed to perform the better

job (shitsuke). At this time, the factory and offices in the world has applied the

philosophy and TPS practices (Toyota Production System) including one of

them is our Company, PT. Citra Tubindo Tbk, Batam.

DEFINITION OF 5SWhat is 5S? This is not just as slogan or words, 5S is the concept of

management in order to manage the work place. In short, 5S is the

methodology and culture to create the safety and comfortable in the work

place. 5S could be applied in the office, building, workshop area, home, or

any social environment.

With this system we can to coordinate how the work place to become more in

order, clean, safe and comfortable, so the activity of our job will not interfere

so finally the purposes (objectives) want to be reached can be met.

5S as abbreviated from Kanji language of Japan Seiri, Seiton, Seiso,

Seiketsu, and Shitsuke. In Indonesia is as the term of 5R, while in English

as 5S.


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TABLE OF ABREVIATION OF 5S

JAPAN

ENGLISH

INDONESIA

Seiri Sort Ringkas

Seiton Set in Order Rapi

Seiso Shine Resik

Seiketsu Standardize Rawat

Shitsuke Sustain Rajin

WHY NEED 5S?

5S as the one basic to realize the World Class Organization (Company) (A

Standard of World Class Manufacturing) prepared to follow every changes

and competition of global era as follows:

Maintain the competition with eliminate (reduce) waste as the care

form toward environment.

Respond toward the customer needs that always changes.

Reduce the long-term cost, reduce wasting the time and reduce

working accident.


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The initial step to other improvement program

Enhance the company image in the eye of the stakeholder,

shareholder and the related parties with the Company.

Enhance the work productivity of the employee, when everything set in

order and clean working environment so it can make the employee can

work comfortable and faster.

THE PURPOSE OF 5S APPLICATION

5S is important and needed to increase the work culture of the employee

through the changes started from the work place.

Working culture

Working attitude

Working habitual

Working behavior

Working place

THE BENEFITS OF 5S APPLICATION

1. Zero Breakdown

It means better maintenance. Example:

a. Scrap, dust, infuriated and pieces in the floor and machine becomes

decreasing;

b. With cleaning the machine accurately and regularly you know the

machine condition anytime;

c. Daily inspection and maintenance could prevent the damage of themachine to become worst in the future day.

2. Zero Defect

It means better quality. Example:

a. If everything is in place, you can avoid taking the wrong goods.


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b. Clean work place will give the high working spirit to anyone.

c. Measurement tool and indicator can work well so the quality will be

better also.

3. Zero Waste

It means reducing cost and enhances the efficiency. Example:

a. Inventory and less of goods is being processing.

b. Spaces are being used for unnecessary goods becomes decreasing.

c. The unnecessary movement such as avoiding and searching becomes

decreasing.

d. Reducing unnecessary production movement such as lifting, putting,

accounting and removing.

4. Zero Set Up Time

It means there is no wasting of time. Example:

a. Because everything is set in order so the wasting time to search the

tool can be depressed.b. Clean work place is able to enhance the efficiency and the person

understand its operational easily, even a training participant can

operate it easily too.

5. Zero Late Delivery

It means capable to meet the timely customer demand. Example:

a. There is no damage production so you are capable to meet the timely

customer demand.

b. Good working environment can run the production process faster, no

wasting and increasing efficiency.


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6. Zero Injury (Accident)

It means better working safety. Example:

a. Clean and shiny equipment is easier to observe the damage and

hazard;

b. If you know where the equipment are being kept, you can take it if

necessary faster.

c. If you put something safely so you can avoid that equipment fallout

befalls you.

d. If there is the fire and earthquake, you know where the emergency

door is and fire fighting extinguisher.

7. Zero Customer Claim

It means the customer put their high level of trust:

a. The factory which is well-arranged and clean do not produce the

damage goods.

b. The factory which is well-arranged and clean is capable to produce the

goods which secure the safety of the user.

8. Zero Deficit

It means the Company always in advanced. Example:

a. If the 5S (5R) has performed better, so the work place becomes

comfortable and interesting, there is no waste, no accident, no damage

of the machine and there is no damage of products. You can meet the

desire and expectation of the customer.

OBJECTIVE OF 5S APPLICATION

1. Clean workplace created, set in order, safe, comfortable and pleasant.

2. Tool and equipment is maintained as well as the building during the

working process.

3. Realization of discipline that is needed to gain work standardization.


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4. Safety and working stability maintained as well as the production quality

during the operation taken place.

5. Improvement of job quality created with reducing variance of output.

6. Improvement of efficiency is well held in each of the department.

7. Its constructive of working climate which comfortable and pleasant,

discipline and appreciation to each other among the employees.


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BENEFIT OF 5S APPLICATION

Basically, better implementation of 5S in the Company will give the good

benefits to the employees, company, supplier, or stockholder (funder).

The benefit of 5S is maintained working environment so it capable to prevent

the working accident, also to change the characteristic of the worker getting

more discipline who having the sense of high awareness to motivate every

person get involve to keep working area in the condition of set in order, save

and productive, then finally will enhance the welfare of the employees,

company and satisfaction of the customer.

For THE WORKER will feel:

Safety

Comfortable

Health

Not get bore (high working spirit)

Positive working attitude (constructive)

For THE COMPANY will increase:

Image (solvent)

Business speed

Profit gained

Its ability

For THE CUSTOMER will get satisfaction because:

Minimize mistake (wrongness)

Speed and proper of services


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For THE SUPPLIER will gain the satisfaction because:

Speed and proper of services

Minimize of mistakes

For THE FUNDER (STOCKHOLDER) will gain the satisfaction because:

Confidence or trust upon its effort

The sample of business


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CHAPTER II

APLICATION, KEY SUCCESS

AND

IMPACT OF 5S (5R) APLICATION

A. HOW IS THE APLICATION OF 5S

Direct support from the top management party toward the implementation of

5S program will very affecting to motivate the entire of employees in the

implementation of 5S program. It is clear, that the commitment of the

Company is being needed to perform this program. Without any supporting

from the top management party, the application of 5S program is very difficult

to get success.

5S could be well implemented, if all of the employees from the top

management, middle, or lower get involved in the process of implementation

of 5S.

In order to the 5S application that will reach the objective being targeted, it is

important to know the activity or task related to 5S so it is able to understand

the direction of implementation of 5S for themselves and the Company.


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1. SEIRI (SORT)

The application steps are as follows:

a. Specify the implementation schedule of SEIRI

b. Implementing SEIRI in each area of their responsibility with sorting of

items in its area is divided into 3 (three) as follows:

Necessary : fixed in working area, but the amount is according

to the requirements.

Unnecessary : unnecessary and not valuable item necessary to

throw away, and the unnecessary item but still

valuable placed on TPS (Tempat Penampungan

Sementara) or Temporary Relocation Place (use

Red Tag); prevailing the deadline.

Doubtful item : placed on TPS (use Red Tag); prevailing the

deadline.

c. Items in TPS is being brought to the internal meeting department to

decided its status, if the Head Department or Manager could not decide,

then to be forwarded to the Steering Meeting Management to be decided.

d. Standardization of SEIRI in the workplace area.

e. The evaluation of SEIRI application and its visualization.


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2. SEITON (SET IN ORDER)


a. Specify the implementation schedule of SEITON

b. Classifying the place of keeping and items (functional, uniform, the

frequency of usage)

c. Preparing the place of keeping and give the label (badge) and regulating

the layout of the workplace

d. Standardization of rules and discipline of tidiness

e. The evaluation of set in order (tidiness) and its visualization

Checklist: Has the process of selecting (sorting) been done and to determine

goods unnecessary in the workplace environment, wasting or thrown away,therefore in workplace floor is not seen again unnecessary goods scattered

around, such as cigarette butts, waste paper, personal stuff, waste PPE,

secondhand cloth, unnecessary tools and waste material.


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3. SEISO (SHINE)


a. Specify the implementation schedule of SEISO

b. Preparing cleanness means and perform initial cleaning

c. Carry out of SEISO in the area (tools or machine), elimination source of

dirtiness cause and system control visual

d. Making routine cleanness schedule in the work area by determine the

personnel who take responsibility toward each of working area

e. Evaluation of clean up application

Doing clean up or cleaning in the equipment or machine sometimes having

the special technique not just the only spraying with the jet pump, but also

ask for the direction from the Superior or the person who more understanding

so there is no severe mistakes toward the machine.

4. SEIKETSU (MAINTENANCE) (STANDARDIZE)

The application steps are as follows:a. Perform discipline order and standardization of SEIRI, SEITON, SEISO

b. Maintain the optimum condition and application of visual control

mechanism, anti-idiocy

c. Determine efficiency targets (productivity)

d. Evaluation of SEIKETSU application and its visualization


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5. SHITSUKE (FREQUENTLY) (SUSTAIN)


a. Applying timely information

b. Applying positive habitual (timely, promise precise)

c. Realizing learning opportunity (determine topic, group, and learning

schedule or discussion)

d. Determine the target (group up to personal)

e. Evaluation of SHITSUKE application and its visualization

B. KEY SUCCESS OF 5S APPLICATION1. Involvement of every person.

2. 5S program demands the responsibility and commitment of top

management.

3. The management must be as the leader of program executor.

4. 5S program must be supported by all of the parties.

5. 5S program must be independent.

6. The management has to perform personal tour to the offices, plant

(workshop/yard) periodically.

7. In the first stage, it must be exhibit the relevant impact.

8. Implementation of 5S program must be in line with the safety program

and other kaizen.


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C. Impact of 5S (5R) Application

The review to the impact of 5S (5R) application both qualitatively or

quantitatively in what unit or field will indicate the increasing of :

Productivity : level of productivity

Quality : product quality or service produced Cost : amount of the cost to be paid

Time delivery : meet the customer needs timely

Safety : safety and working health

Moral : working spirit of the personnel

Work environment : working environment


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CHAPTER III

5S AUDIT

The implementation of 5S audit is performed by the team has been

commissioned to assess the implementation of 5S. In addition, this team also

performs the documentation (taking the photograph) at the place requiring of

attention.

5S audit is performed at least once a month with the controlling time every

week then to the area/department/group which much successful in

implementing 5S program in the period of 3 months, 6 months, respectively,

will be given the reward (if any), while the lowest in its assessment will be

given the warning. Below is the kind of 5S audit performed by PT. Citra

Tubindo Tbk :

1. Internal Audit

Audit is being performed by the Auditor or Auditor Team (> 1 person) fromits own department once in a month is on January, February, April, May,

July, August, October, and November.

2. External Audit

Being performed by the Auditor from Steering Committee Team or from

another Company in the area specified once in 3 months is on March,

June, September, and December.

To know the successful of 5S implementation it requires to arrange the

evaluation or 5S audit as the investigation toward weather the implementation

of that program was good or not and how its effect toward the employees.


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The announcement of 5S audit outcome will be announced to all of the

departments and managements, so it will encourage the implementation of

5S will be more increased continually.

AUDIT ACTIVITY

Preparation of Audit

Review

Preparation for Field Audit

Implementation of

Field Audit

Preparation and

distribution audit report

Completion of Audit

Audit Follow-up


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CHAPTER IV

THE ACTIVATED FACTOR

AND

STANDARD OF 5S (5R) IMPLEMENTATION

A. Driven Factor

A.1. The Commitment of Top Management

a. Company Policy

The top management has specified the policy (stipulation,

determination) of the Company related to the 5S application in the

Company.

b. Top Management Agenda

The top management will attend to the 5S special program (kick

off or tool box meeting, morning briefing, giving the reward,

direction, and so on).

c. Company Program

The effort of 5S application and enhancement has beencontained in the company program such as DQO (Department

Quality Objective).

d. 5S Management of Organization

The member involvement of top management corps in the 5S

management organization.

e. Field Visited

The top management will carry out the field visited to know the

development (progress) of 5S application.

The top management has shown the commitment toward the 5S

application and development (to be understood, communicated, carrying

out management review and ensure the resources availability).


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A.2. 5S Organization

a. The formation of 5S organization

5S organization has been formed in the Company.

b. The meeting of 5S organization

Routine 5S organization meeting to discuss the 5S application

program has performed.

c. 5S Area/zone distribution

The entire area in the company has been divided into 5S detailed

area (zone).

d. Responsibility party and program

In every 5S area (zone) has specified the working group

responsibility party and has have each work plan.

e. 5S administration

The administration of 5S application has been well documented.

A.3. Training and Promotion

a. Explanation (training)

All of the company personnel from its superior to subordinate gotthe explanation (training) and has been well understood about 5S.

b. Spreading of Visual Reinforcement

There has been visual reinforcement about 5S in the 5S area

(zone) in the company to socialize 5S (to be written, banner,

poster, logo, slogan, merchandise, and so on).

c. 5S information board

In every 5S area (zone) has the 5S information board with the

relevant and actual of information material.

d. Target and objective

Target and objection of 5S application program has socialized and

to be understood by the whole of the company employees.


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e. Outcome information and impact of 5S application

The outcome (impact or advantage) of 5S application for the

company or personnel has to be informed and socialized to the

whole of the company personnel.

B. Implementation of 5S (5R)

B.1. SEIRISORT

SEIRI is the activity to separate all something goods that really

necessary and then throwaway unnecessary goods from the workplace.

In the work place there are so many things can often causing of

operational disruption emerges in working, such as about the

complaint of every person that complaint his or her narrowed

workspace because of too many stuffs.

Keeping the useless stuffs or the stuffs is being used but

excessive that causing the disadvantages as following:

In the narrowed workspace will increasingly emerge the

impression that the room (space) more narrowed and

uncomfortable.

Usage of working area becomes less productive.

Rack and filling cabinet, its usage becomes ineffective.

Becomes more difficult to distinguish which the needed stuffs

in the work place and not.

Keeping the excessive stuff is like having a lot of money but

did not being kept in the bank (loss of bank interest).

Letting the goods condition becomes rusty, damage or

ancient is like wasting the money.


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Having the excessive stuffs in the production process could

impact in many factors such as lowering the quality, damage

of the machine, late of raw material and disadvantages in the

time when machine setting up.

Allocation more time in the inventory inspection will increase

the expenses and causing chained-reaction upon the loss in

the future day.

How to know that actually we are keeping the unnecessary

goods or we are keeping the goods excessively?

Try to investigate around of you in the following places and you will

find the stuff is exceeding the requirements.

Investigate racks

Check the unused and useless stuffs

Check another stuff other than specified stuffs

The upper and lower rack as the main place to keep this

stuffs

Investigate locker (wall-cupboard) of toolkit, drawer, and

cabinet

Check all of tools such as hammer, cutter, gauge, and others

Check gauge such as compass, slide-gauge (vernier) and

dial gauge (indication gauge)

Check the personal stuff usually kept in here, such as

magazine, meal equipment, and others

Investigate the floor

The end-section or corner of the floor as the place requires

attention.


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Check heavy equipment is not being used and unnecessary,

trolley.

Generally, among the production goods there is raw material

heap or waste material is tending to experience of lowering

the quality.

Check among the production goods that quality unknown

usually being heaped in the hidden place. Such as being kept

under conveyor, under the window, under the workbench,

and around the path line.

Check the oil bin, is the kind of wasting is being prohibited to

be used in the factory.

Investigate spares storage and raw material

Check spare-part and raw material which during through

years never been removed and dusty, requires the attention.

Investigate outside working area Check the raw material which is not removed as long as for 5

years and have been rusted.

Check trolley palette and container that are not being used

but still being kept.

Check the rest of raw material heaped.

Check the machine and equipment are not being used but

still being kept.

Investigate office (inc ludin g the off ice l ies inside the working

area)

Check rack, wall-cupboard as the place of document and

wall-cupboard as the place of unused documents.


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Check sample product, demonstration product, catalog and

others.

Use RED TAG technique to assist this stage.

Steps are as follows:

Prepare RED TAG that already available.

Perform Genba (to the work place). Hang RED TAG to the

object unnecessary in that area. Throw away immediately if

the object is known as the invaluable waste. Follow the

procedure of valuable product wasting by communicating it to

the Superior and use write off.

Remove the object given RED TAG to the TPS (Temporary

Keeping Place) to be evaluated of follow up toward that

object. The depository deadline is 2 weeks, if needed further

review no longer than 30 days to 3 months (if required).

Recording to the RED TAG log book and take a picture if

necessary, this log file as the reference in the future day.

If the object is being RED TAG has to be decided, loose RED

TAG bearer, then returned to its place.


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B.2. SEITONSET IN ORDERTIDY

SEITON is the activity to organize the layout of equipment, supply,

material or activity goods so it is easier to search, find, and return it, also it

emphasizes of safety, quality, and effectiveness.

Why should we wasting time to SEARCHING?

The many scattered and unused goods around of us, causing we

must to search the object is being needed.

There is no adequate place to keep

There is no indication label

Wrong keeping

The procedure to minimize this SEARCH action can be divided into

7 (seven) steps as the following:

Throw away everything useless. Follow the important facts

explained previously in the SEIRI topic.

Clean the depository racks. Using the space for racks and place of

keeping the file is specified in the SEIRI must be sub -grouped

again. Besides, additional rack is being made as minimum as

possible with considering the presence of requirements and proper

arrangement.


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Specify the repository

Arranges the meeting to specify the manner to keep easily and simply

considering the matter as follows:

Goods is often being used must be kept close to the user.

Goods is often being used must be kept in the place as high as in

the part between elbow and shoulder.

Goods is seldom being used must be kept in other place by

distinguish it according to the usage (collect all of the goods seldom

being used in the same place). Store that goods by same of usage

in the specified place such as screwdriver must be kept together

with the screwdriver, collect it when it is being used the parts

necessary from each place to be paired.

Make the mark which show its repository

Why we need to make the mark which indicate the repository?

Imagine that you are looking for the coin in the drawer in the coin

repository which do not have the number of drawer or room of patient inthe big hospital which do not have the number of the room that you have

to visit one of your friend in that hospital, you can imagine what will

happen.

The mark of the repository can be divided into 2 categories (this part

is important technically). The first category is location mark and second

is equipment label.

Location mark

-- Certain rack number (code) indicates the place of that rack.

-- Meeting room, parking area or locker must be having certain

number (code).


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-- Anytime we need to take something we have to understand

where its repository.

The way to determine the number (letter) of location mark

Determination the number (letter) must be simply and do not too

complicated so every person can remember it easily. For example

rack is being close to each other will be given number 1, 2, 3, or

the letter A, B, C, starting from left side and each of rack must be

given label with the number (letter) alternately and vertically.

Equipment mark

-- A symbol that indicates the type of equipment will be placed on

the rack where the place of the rack will be.

-- In the hospital the name of the patient must be printed in the

rooms door; in the parking area the car which is hired for the

long-term the car license-plate or the name of vehicles owner

must be printed in the place of that owner whose park its car.

Why we need label?

The professionals disbelieve the opinion that although rack do not

given label but whatever exist over there can specify what the form

is looks like and telling its content.

The equipment has been used must be returned to its repository

consistently.

If the rack is not given the label yet, you must be grumble and

complain because there is someone who did not keep it in its place

again, dont you? What is being used?

The goods has been kept must be given label too.


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With this label we know what is being kept.

If the goods are the demo goods, make the record about the

demo that explains the type of job to be demonstrated. Another

example, such as the employee must wear the identity card and the

car has the number of vehicle.

Why is it necessary?

To ensure again whatever is to be kept in that rack is what we need.

How to display label Label attached in front of the equipment should be easily seen,

distinguishable, and easily to be understood even by one of the

worker who did not know at all the way of the machine work.

The equipment is being used collectively without label which

distinguish it, it is better having the number or symbol that showing

the difference size (try to imagine if there is no distinguished

number lies behind of the back of an athlete). Use many kind of

appropriate color standard.

Where the goods lied should be contained in the table.

Rack location must be recorded in the table.

To distinguish the properly location what is to keep, it is by

registering what goods are contained in the rack in the table

according to the type of the product and production process. For

example the tuning machine table, standard of production and table

of inspection.

One of our friends to be brought to the hospital to get the medical

treatment. If there is someone who visit him or her so he or she will

record the name of the hospital, place and the rooms number of

that patient so anyone between us can visit him or her easily in the

properly room.


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Requirements

If registered in the form of table, although without any completed

explanation we still easily to seek and gain what we need.

The way to display properly

Anytime we need to take the stuff required from many kinds of

place to be used, so we can economize the time if we follow the

order shown in that table. Therefore, the display must be easily to

be recognized so it can economize the time of searching of the

goods.

The inspection of giving the repository label to return to its place to

maintain the normal condition. Such important factors to maintain that

condition as specified.

1. Anyone is mandatory to place the equipment according to the label or

as specified. Therefore, for that reason it to be needed the mechanism

to ensure that everybody in that area has understanding the

mechanism storage and the returning of the goods in that area.

2. We can carry out the innovation or find another way in the name of

practical simplicity.

3. Joint agreement is :

The assessment to prove that its implementation according to what

has been specified

Unless, find out the area which is not fulfill the standard

This area must be repaired immediately

(All of the three factors mentioned above must be continually

repeated to gain the appropriate implementation)


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The mark or label must be easily to be check or easily recognized if

in the wrong placement.

-- Everything that is in the wrong placement or inappropriate with the

label must be placed on the place easily to be seen.

-- Although has been undergoing the joint inspection with any person

from other department, outside party or even the president or every

person basically who did not having the knowledge about that

department, after see that mark and label must be able to say that

something being placed on inappropriate location specified.

B.3. SEISOCLEANSHINE

SEISO is the activity to clean the work place, machine, equipment, and

working equipment from dust and dirty that is sticking, is being done

routinely so it is always in the clean condition and out of damage,

degradation and abnormality.

Clean the floor (sweeping, omit and clean the dirty).

Surrounding the working area with the pleasant feeling

The cleanness of the floor is as the first step to form the good

relation with the work place. In addition, this condition is having the

great effect so every person will stay and ready for work over there.

The shiny condition can influence human psychologically with

making them feel comfortable and not being stress.


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Being realizing the importance of tidiness aspect, cleaning the floor

is as the next priority after throw away all of useless or unexpected

goods.

The important steps:

First, start to clean using broom.

At least sweep the work area completely and throw away all of

things no use. While certain work area must be with the special

technique of clean up the floor from oil, coolent and so on must

follow that technique.

While holding the broomstick or other hygiene equipment, the

Superior can sweep the floor and neat his or her own workroom to

exemplify to its subordinate.

Determine the border to divide the area.

The separation line for walking

Determine the symbol in the floor such as there is no barriers in

that area and so on

The picture in the floor is showing the location usually there is the

object in small size such as trash bin, fire fighting extinguisher, and

so on.

Eliminate the causative incidents of dirty which can make that area

being dirty.

The oil machine leakage. Trace the leakage and then repair it.

The water leakage from water tank or pipeline Make the record of the event and then repair the damage

respectively from its source.

Dust and spreading particles

Use the cover, repair the cover or move the cover to the

appropriate place


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Check the product and transportation material system (is it leak,

spill or over loading)

Repair or set the dust ventilation system

Sweep and clean the small area often ignored

Clean trace of oil in the floor with the cleaning agent

Perform painting or brush with wax to prevent thick dirty

In the area where the accuracy and precision of the working

equipment is to be needed such as in the laboratory it must be the

action taken to prevent extremely toward the dirty such as dust and

rest of dismissal. Therefore, you are advice directly to use your

hand to touch the dust is sticking above the floor.

Perform the cleaning carefully and develop the better environment

in the following area.

Surrounding the floor, wall partition, wall and corner

Upper side, inside and under the machine

Up of the roof, corner and the other side along the pipe

Light-bulb tube and its corner

Upper and under the desk including around the rack

Outside upper and inside the container or boxes, storage rack

Path or around the pipe racks toward the wood cutting shiver and

other trash

Inspection of the machine through the cleaning. Cleaning (wipe with

the hand) is as the simple way to check.

Although you are not mastering the machine as professionals, if you are

wipe with your hand, you can feel there is something wrong in that

machine. So in this case we can detect whatever damage generally to be

ignored in common. This is called as the inspection of the machine

through the cleaning).


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The machine is being dirty will difficult to maintain.

The dir ty machine is the consequence of negl igent

The machine is being dirty always be ignored and not to be check

carefully in common.

If the completely inspection is not to be done, the unpredicted

damage previously will occur and tend to be causing much more

trouble.

Therefore, the machine will be less cleaned up will usually causing

the trouble will be repeated again.

The inspection procedure with cleaning. The main factors. Pre-assessment

Perform the inspection with cleaning up

The involvement of technical advisor

Other the inspection with cleaning, try to find the small spots to be

seen

Pre-assessment by the meeting of the member

Collect information related to the type of issue and the frequent ofcausing of the trouble

Determine the sounding upon the big issues occurred with the

reason and outcome accompanied it

Choose the factor is most possible to become the reason of

causing the trouble


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B.4. SEIKETSUMAINTAINSTANDARDIZE

SEIKETSU is the activity to maintain the work place facility, machine,

equipment and goods regularly so that:

No longer to be met the unnecessary goods in the working area

(S1)

The work place becomes more tidy (S2)

Free from dirty (damage) (S3)

The optimum condition can be maintained and to be kept (S4)

In the same time the application of visual control (visual control

photograph) as the means of improvement can be assumed as the

standardization because it able to enhance the visual auxiliaries to ensure

the implementation toward to the right direction. Therefore, S4 can be

divided into 2 main parts as follows:

Standardization to maintain the stability of S1, S2, and S3

Standardization through the visualization so the implementation

able to run properly and fulfill the standard (visual control)

Standardization to maintain the first Three S.

1. The steps in standardization

In determining the standard, the participation of the entire small group

in the organization will be needed. The standard will be specified by

each of the small group after applying the first three S, then by the

management will determine the minimum value at 80 for the year of

2014. Each of the small group will determine the standard each of


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group that will be discussed in the discussion. Equipment, goods and

area with the similar characteristic must have the same standard which

the further more things will be fixed in its status in every small group.

So it is with each of the department must determine the standard and

discuss the improvement needed through the same process with that

small group. In this case, to determine the standard of each group,

then perform the adjustment or improvement to meet the organizations

standard.

Set standard area

Discuss the standard specified by each of small group and

improve the difference to meet the standard of department

Collect the standard of department to be developed as the

collective standard of the Company

Make the improvement so appropriate with the new standard

specified by the administrator (the standard of the company).

Then apply that standard in the group.

2. The principles to determine the standard

Determine the standard in the area such as floor, walking path,

wall, ceiling, door, window, and curtain.

Determine the standard in the object or equipment being used in

the different location that possibly cannot be applied, such as in

the office, toilet, pantry, meeting room, first aid room, workshop,

repository, machine and so on. For example, the equipment

requires the standard determination in the office.

-- Workbench

-- Chair

-- Wall-cupboard and filling cabinet

-- Whiteboard

-- Telephone


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-- Photocopy machine

-- Trash bin

-- Fax machine

-- Door label

-- Racks

-- Electrical, lamp light, electric socket, connector and kettle

-- Fan

-- AC (Air Cooler)

-- Key holder and so on

Example: Equipment or item requires the standard determination in the

rest room (toilet).

-- Finger bowl

-- Lavatory

-- Roll tissue

-- Mirror

-- Hand dryer

-- Trash bin-- Soap and so on

3. Table of 5S Implementation (5S Standard Activity Form)

Each of work area must make a table of 5S time clearly consists of the

schedule of ignition and cleaning inspection, standard photo of work

area and recording of the findings to be done of the improvement. The

schedule of Big Cleaning Day (General Cleaning)can be inserted too

to this table. Example:


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Table of 5S implementation in the office or workshop (plant)

exist in each of work area.


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The schedule of activity in office held at least once in a week

while in workshop or plant, such as at the Yard perform the

5S activity in daily basis on Monday morning while at other

workshop is to be done before and after daily working.

4. 5S Audit Schedule

To motivate and measure the outcome from every improvement to be

done, an audit must be done every month is from on date 1 up to 15.

Canceling and delaying cannot be accepted, unless there is very

important problem arisen. In this case, to prevent the employee that

ignores the importance of an audit and appreciation to the 5S activity

consistently.

5. Determine the standard of control visual

Among all of five human senses, the eye is assumed as the best signal

receiver before the message transmitted to the brain. Therefore, the

various communication method to be tested to ensure the mosteffective visualization method will be applied so that it able to

understand the fast and accurate message. In the manufacturing

factory, the ability to understand the way the machine can be operated

quickly, to ensure reduction of the damage will be occurred. This in the

main reason why the visual control is being done in the manufacturing

factory today. For the office block the visual control will assist to reduce

the time being wasted useless for searching the equipment (goods)

being kept in somewhere. With application of the visual control the

entire organization will increase its ability to yield and perform

effectively and efficient operational.


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Types of visual control

Label, either symbol or letter, for example:

Use the symbol of colored sticker to indicate the control of

lubricating oil.

Use the label (sign) when handling the complicated working

process.

Use the sign or sticker to indicate the inspection of the

equipment in the assessment period.

Sign will indicate the temperature of the machine

Use the sign to indicate the responsibility

Other types of signs


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Control limit

Use the symbol that indicates the measurement status such

as the normal or abnormal condition and the actual condition.

Use or exhibit using certain symbols that refers to the normal

condition such as the Match Mark.

Use the symbol such as the line or spot to find the repository.

Smart visual

Use the transparent material so it able to see inside the

machine to understand the way the machine can be best

operated.

Make the indicator that showing the machine condition.

Make a map states that the area or location is having the

problem must to be treated carefully in the factory.

Create the more effective and faster way in tracing the level of

storage of the equipment.

Example: Type of different visual control

The sign or symbol that refers to the safety

The sign or symbol that is preventing the mistake of using the

machine

The sign or symbol for the equipment repository

The lines that indicate the zone or distribution of area

Indication of condition or abnormal situation Labels of the machine, equipment and location

Direction labels of arrow of pipeline of water, gas, oil,

chemical, and so on

Procedure images of work flow (work flow process chart)

The signs indicate direction of way


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B.5. SHITSUKEFREQUENTLYSUSTAIN

SHITSUKE is the activity to civilize and habituate of working according to

the system and procedure as well as the development of positive working

behaviors of the employee in the work place as the discipline habitual.

In order to 5S is able to give the satisfactory outcome, these

following factors must be met:

1. The ability to develop S4 (Standard determination) is the ability to gain

the full cooperation in determining the base standard. Therefore, with

determining the strong base then the application of 5S can be

implemented with the most effective way.

2. Making the Monthly 5S Inspection Sheet has been taken from the

standard procedure specified in the S4.

3. Performing tightly 5S audit every month with planning the annual

schedule that is date, time, area and the inspector to perform the

assessment (audit). Do not perform cancelation or delay and visit

unless the condition which very abnormal happened.

4. Perform the weekly or monthly meeting of small group, department and

organization. This meeting will ascertain again that those activities are

going well because the problems can be predicted are open to be

discussed that is consisting the group brainstorming in handling the

problem, so it is reduce the communication barrier between the

members of the group.


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After it has been applying 5S for 3 years, it required the consideration to

increase assessment standard (DQO Minimum Score), example: in 2012

minimum score per audit of area is 60, in 2013 it becomes 70 and in 2014

is 80. If the outcome indicates reduction of damage in the working process

then the system of 5S has formed in that organization. Likewise, the

determination of new standard to S4 must be considered as the better

standard so it can increase the entire productivity.

* Evaluation

Evaluation Procedure

The evaluation process of 5S activity made based on the score making

system related to the objective specified previously with the score weight

higher toward the important activity. However, the total appraiser equal to 100

point or one score of the percentage. The evaluation process must be

performed every month with determination of date and time of inspection.

Area will be evaluated have to give the written report toward the progress has

gained to the appraiser of their every visit to be done. The appraiser (auditor)will fill the 5S assessment form according to the report and the actual area

that will be inspected then make the comment and advice of improvement if

necessary. Furthermore the score has been accounted will be sent to the 5S

coordinator and to be compared with the outcome has gained in that

organization before making the final conclusion upon the entire activity

progress.

The standard assessment S1-S5 will be made according to the assessment

of the auditor where each of the auditor will assess the outcome and account

the average of final score or perform the meeting that is discussing each of

the point of view of auditor before conclude the score for each of the area to

be valued.


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The assessment will be performed in the three level of different position that

are inside that own group, then the level of chief of the department (middle

management) and the level of director (top management).

Note. Internal team has to assess their performance consistently every month

even after has passed the final inspection by the head of the department and

top management to ascertain again the best standard.


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CHAPTER V

6S (5S + SAFETY)

Safety must be as the main priority in the working activity. Although, you

cannot increase the safety before other S component that is 5S fulfilled.

The awareness concerning the importance to the safety must be emerged in

order to minimize the accident happened, injury or other incidents. Therefore,

each person must have the role and responsibility in the case of safety as

well as understanding how is the way to prevent the accident happen. Every

person who having the role and responsibility in the case of safety must

observe too and correcting if there is the behavior of the fellow worker who is

ignored the safety.


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The first thing must to be done is hazard recognition is covering analysis to

recognize the hazardous situation emerged by the equipment, material, up to

the environment in the certain work area. If the hazard found, then utilize the

certain sets of equipment that can be used to enhance the safety.

The last S (safety) added to 5S to become 6S or 5S + 1 as one of the main

part in the ergonomics. 5S itself has been in line with ergonomic and it can be

said as the part of ergonomic. Ergonomic is the science about working, while

5S is the method to arrange the work place and optimized it. With the 5S so it

can be created the better working morale as well as it the most important is

the effectiveness, efficiency, and increased working productivity, it means

generally it can enhance the working performance. This case can cause 6S

become an issue that close-related to the ergonomic.

In order to win the competition in the global competition era, the company or

organization demanded to be efficient and effective in every line. The system

presence today is offering many ways that if it is integrated-implementationand it supported by strong and trained Human Recourse so it is possible in

the brief tempo will place the company or organization in the World Class

Category.

5S + 1 (Safety) as the one of the system is offering the way to upgrade the

company or organization performance with the focus in the working

environment organization effectiveness and standardization of working

procedure. 5S + 1 (Safety) will simplify our working environment, also to

improve the quality of efficiency and working safety.

5S + 1 (Safety) as the most elementary system to enhance the working

productivity by growing on the forming of job ethos from the employee to

make its working environment being comfortable and safe, so will arise the

sense of feeling that it is in the future will encourage the worker to perform the


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improvement toward its working environment and training them to reduce the

redundancy, downtimewhich is unplanned and in-process inventory.

After integrated implementation and application, 5S + 1 (Safety) will increase

the workers morale, create positive impressions from the customer and

enhance the company efficiency as well as the organization. The worker is

not just feel comfortable with its working environment, the effect to perform

the continually improvement will encourage reduce in redundancy, the better

quality and shorter lead-time. All of these in the future will make the

organization become more benefit as well as competitive in the world market.

5S + 1S Philosophy

The improvement process if fully applied and continually will give:

The influence of morale enhancement from the worker holistically

Create the positive impression from the side of customer

Enhance the company or organization efficiency

Why do we need to apply 5S + 1S

Tidiness and cleanness of working environment will give comfortable,

health and safety to the worker

Tidiness and cleanness of working environment will increase the

working productivity

Tidiness and cleanness of working environment will increase the

efficiency toward working time

Tidiness and cleanness of working environment will produce the high

quality product with the lower amount of defect

Tidiness and cleanness of working environment will promote the

organization (company), visually control and cleanness toward to the

customer or candidate of the customer.


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CHAPTER VI

CLOSING

And there is no enjoyment to be gained, except after hard working

(previously),Arabian aphorism.

Dear reader, with the strong will and full of confidence, lets create the 5S

culture (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) with all of the potential

available to gain every opportunities in front of us. Prepare yourself with the

high motivation to better step forward with the 5S mission and precise

strategy. Then, complete with our best movement.


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(Back cover)

SYNOPSIS

You are probably often experience the condition where there are much stuffs

sprawled, irregular, untidy, unsightly, dirty, seldom to be used, damage or

even it has not being used anymore. There will emerge the redundancy, time,

cost, energy, thought, and so on. The productivity and the high level of

accident because less of awareness and self-discipline. You are probably can

experience the similar things in your home, your social environment, or even

more in your work place.

Therefore, it is right if you decide this Manual Book of 5S as the proper

solution all at once as the reference because it is arranged according to the

experience and practical in our company.

What are you waiting for, got a move on immediately and create the good

working environment start from our own self, so our world will be as theheaven of life that is having the meaning, high-grade and comfortable.

Copy right 2014

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