STM Quality Limited

Introduction to 5C

TOTAL QUALITY MANAGEMENT

5C
ABSL Quality Solutions 2007 STM Power Limited

Application of 5C
OBJECTIVE: To raise the level of

STM Quality Limited

understanding on the practical application of 5C within the workplace Why: In order that employees can apply & transfer that learning into their own areas of responsibility How: By a practical step-by-step training approach

STM Quality Limited

What is 5C?

STM Quality Limited

Structured approach to the application of:

- Housekeeping - Associated improvement activities It focuses activities towards: - Improving the workplace: health & safety, quality & efficiency - How we operate within it - Eliminate waste in all its forms
STM Quality Limited

Why Apply it?

STM Quality Limited

To create a cleaner, safer & more cost effective company by: Removing unnecessary items in the workplace Controlling/labelling stock inventories & essential items Standardisation in the workplace Identification of potential safety hazards
STM Quality Limited

Considerations

STM Quality Limited

It requires: A disciplined approach to make it happen Visual involvement & commitment from all Maintaining all areas, not just the shop floor Recognition of a journey, not a race - Not everyone will be committed!

STM Quality Limited

Considerations

STM Quality Limited

Commitment to 5C: Why will people not What can we do about it? - EDUCATION - INVOLVEMENT - COMMUNICATION
5C

be committed?

STM Quality Limited

What Are The Elements Of 5C?

STM Quality Limited

CLEAR OUT - Remove unnecessary items

CONFIGURE - Layout - agree storage spaces

CLEAN & CHECK - arrange daily cleaning

routines CONFORMITY - Maintaining a spotless workplace CUSTOM & PRACTICE - day to day operation of the new culture in the workplace
STM Quality Limited

Where Did 5C Come From?

STM Quality Limited

This came from the Japanese who use 5S:

CLEAR OUT (Seiri)- Remove unnecessary items

CONFIGURE (Seiton)- Layout - agree storage

spaces CLEAN & CHECK (Seiso)- arrange daily cleaning routines CONFORMITY (Seiketsu)- Maintaining a spotless workplace CUSTOM & PRACTICE (Shitsuke)- day to day operation of the new culture in the workplace
STM Quality Limited

Where Do You Start?

STM Quality Limited

CLEAR OUT!

STM Quality Limited

What Are The Elements OF Clear out?

STM Quality Limited

1. CLEAR OUT - remove unnecessary items

Photograph the area

prior to starting Identify unnecessary items & apply red tag Apply tagging rules Date Description Location Deal with tagged items Eliminate defective items & dead stock

STM Quality Limited

Red Tag Process

STM Quality Limited

The term unnecessary items means: things that are not

needed for current production As soon as an unnecessary item is found it should be identified with a red tag & moved to the appropriate area Retain any item to be used within the next month according to the current business requirement - tag everything else Date Red tags are to draw attention to items: Description Location - that must be actioned upon - which should also remind people of safety & cost Clarify WHY red tag has been attached & decide on action!

STM Quality Limited

Where now? - Configure

STM Quality Limited

Allocate a place for everything

Ensure all areas are clearly identified e.g.

gangways, work areas, etc. Establish rules to keep everything in place Arrange items for quick access when required, in the quantity and quality required Eliminate searching, organise the workplace
STM Quality Limited

STM Quality What are the elements of Configure? Limited

2. CONFIGURE - Assigning storage spaces Visual identification within the workplace

Standardisation of storage

- KEY - ACCESS TO ANYBODY, IMMEDIATELY

3 POINTS 3 KEYS

1. Can see 2. Can take out 3. Can return

- Where? - What? - How many?

Fix position Fix items Fix quantity

STM Quality Limited

But Everywheres Dirty!

Dirt can create hazards!

STM Quality Limited

Cleaning can identify problems!

STM Quality Limited

What are the elements of Clean and Check?

STM Quality Limited

3. CLEAN & CHECK - Consolidate daily cleaning

Decide what to clean
Decide who is in charge of each cleaning task Decide on cleaning methods

Prepare cleaning tools & equipment

Implement cleaning

STM Quality Limited

Maintaining 5C Monitor and Audit

SECTION AUDITED: AUDITOR: ___________________

STM Quality Limited

Example of production workplace Audit Chart

DATE:______________ NON-CONFORMANCES AND COMMENTS SCORE MAX 10

ACTIONED BY
DATE

SCORING
CRITERIA:
10- EXCELLENT. NO NONCONFORMANCES 98- GOOD BUT MINOR FAULTS WHICH LEAVE ROOM FOR IMPROVEMENT. 76- AVERAGESEVERAL NONCONFORMANCES 54- POOR-REQUIRES CORRECTION & REAUDITING. 32- VERY POOR & POSSIBLE SAFETY PROBLEMS. IMMEDIATE ACTION REQUIRED & RE-AUDIT. 1-

GUIDELINES:
GENERAL CLEANLINESS
LITTER ON FLOOR; ACCESS TO BINS; BINS OVERFLOWING; GANGWAYS CLEAR; ETC.

EQUIPMENT STORAGE
TOOLS PUT AWAY; PRESS TOOLS & JIGS CORRECTLY STORED; ETC.

COMPONENT CONDITION
CORRECT LABELLING; BINS OVERFLOWING WITH JOBS; RUSTY COMPONENTS

MACHINE CLEANLINESS
SLUGS; EXCESSIVE OIL; CUPS & RUBBISH LEFT ON MACHINES

WORK AREA CLEANLINESS

WORK SURFACES FREE FROM NEWSPAPERS, WRAPPERS, CLOTHES ETC.

STM Quality Limited

Keep It Neat And Tidy

STM Quality Limited

What can be done to prevent accidents & untidiness?

Ensure cleaning procedures are maintained Ensure everyone is involved & knows how to

maintain standards Remember SAFETY is the prime concern Ensure improvements are displayed & everyone knows Develop ownership & pride in our workplace
STM Quality Limited

What are the elements of Conformity?

STM Quality Limited

4. CONFORMITY - Maintain a perfect workplace Maintain established principles Review checkpoints - no unnecessary items - Stocks & tools are accessible - Cleaning being carried out Develop an organising checklist Agree a frequency of checking, responsibility & follow up action procedures
STM Quality Limited

How Can We Improve 5C?

STM Quality Limited

APPLY all 5 steps of 5C MONITOR & review

frequently & consistently OWN your own workplace WHEN you make improvements: SHOUT IT! - take pride in achievements DONT STOP continuous improvement
STM Quality Limited

What are the elements of Custom and Practice?

STM Quality Limited

5. CUSTOM & PRACTICE Visual control Take more photographs Create an auditing mechanism appropriate to the area being checked Establish action/audit patrols - every area, regularly & publish results

STM Quality Limited

Maintaining 5C - Dont wait until its too late!

REGULAR CLEANING

STM Quality Limited

DONT WAIT UNTIL

ITS TOO LATE!

ORGANISE & MONITOR

STM Quality Limited

Summary Approach
Apply 5C in a step-by-step approach

STM Quality Limited

Ensure clear communication before starting activities Ensure ownership is established & understood Ensure involvement of the people in the area Set standards at each element before progressing Remember 5C is the responsibility of all, not just the

few!

An ongoing improvement activity

a way of life!
STM Quality Limited