T5S

S.No. 1 Level 5 All know what is 5S & Understanding Many do not know about Two Persons could not One Person could not No one knows what is 5S. can broadly explain 5S, 5S. explain about 5S. explain about 5S. meaning. [5] 0.00 1.50 2.50 3.75 5.00 Parts & semi-finished Some parts & semiSome parts & semi- There are no materials in Passage maintenance is Passage goods are scattered here finished goods are placed finished goods across the passage. All within habituated (Clean and no maintenance & there. at some places. yellow line. yellow lines. materials). [5] 0.00 1.50 2.50 3.75 5.00 Unneeded materials are Unneeded Unneeded materials are in Unneeded materials are All defected & excess in the working area. One unneeded material materials and the working area .Many in the working area. A few material is treated as per Three such things can be could still be seen. Machine 5S things can be seen. things can be seen. plan. Fully habituated. seen. [5] 0.0 1.75 2.75 3.75 5 There is no separation of There is a plan for There is location of NG, There is location of NG, Defected & OK,NG & Remained separation of OK,NG & Remained materials with Problem is related to Remained materials but Excess material materials and no plan / Remained materials by proper process to treat improvement. no process to treat them. responsibility. certain timelines. them. [5] 0.00 1.50 2.50 3.75 5.00 1.Some 1.A few items have Identification labeling is Identification 1.There is no Identification 1.All items have materials/Instruments etc. missing identification standardized and is labeling labeling Identification labels. have Identification label. labels. followed habitually [2.5] 0.0 0.75 1.5 2.0 2.5 2.Yellow marking missing 2.Yellow Marking is 2.Yellow marking done 2.There is no Location 2.Yellow marking done for in some section/ areas standardized of particular location marking for whole area and well marking. 50% area. inconsistency in specification and is maintained. maintenance. followed habitually [2.5] 0.0 0.75 1.5 2.0 2.5 1.Do have dust bin stand 1.Brooms/pans/polythene brooms/pans/polythene 1.Brooms/Pan/polythene but no brooms or pan to missing from a few missing from one available at every enable workers to clean. locations. location. location for cleaning. Dust bin, Polythene missing. No concept of dust bin Brooms & Pan stand. Overflowing dust 2.Counted stands. and garbage Proper cleaning of bins 2.Disposal frequency 2.Systems exist & no Information available at disposal garbage bin does not match with information of overflowing every location for information(checklist) respect to time garbage. cleaning and is being displayed and followed followed habitually [5] 0.0 1.75 2.75 3.75 5 1.There is some There are screws, scarps, 1.Generally clean & all Shop Floor dirt/Cobwebs and 1.Improving working dirt, tyre mark etc.Toilet operators clean their 1.Always found to be cleaning and operators have started to environment & pollution very dirty,choked ,stinking working area. Locker clean. Toilet clean their working area source . smell. No checklist room is clean. occasionally. [5] 0.0 1.75 2.75 3.75 5 Check points Level 1 Level 2 Level 3 Level 4

3R( RIGHT LOCATION, RIGHT QUANTITY & RIGHT CONTAINER)

Right Location Identification (Depot, Consumables ,Parts, Semifinished good, WIP, Stands, Trollies, Pallets etc.)
[2.5] 10 Right Quantity (Line/Depot) [2.5] 11 Right Container [2.5] 1.Right Location identified, Board installed but things are not kept as per identification. 1.Location identified and things kept as per markings/boards with max/exception.

1.No Location marking & things kept in disorganized manner.

1.Location identified , but no maintenance.

1.All things kept as per identified locations.

0.0 2.No concept about right quantity. 0.0

0.75

1.5

2.0 2.At least are case found where right quantity does not match. 2.0 3.>75% adherence but containers are not maintained in good condition. 2.0

2.5 2.Some process followed even consumables. 2.5 3.All containers are in good condition. Details of material & container is mentioned. 2.5

2.Max quantity mentioned 2.Max quantity levels for all but do not generally mentioned for some items. match. 0.75 1.5

3.No Concept about Right 3.Right Container defined. 3.Right Container defined. Container. Some material Only 50% Adherence to the Upto 75% adherence to the coming in multiple types of same. same. packing/boxes. 0.0 0.75 1.5

Visual Management
T5S map does not exist. T5S map is prepared, T5S map exist & displayed With an odd exception displayed & updated. but people do not know everyone about T5S map & People having names on what is that. their role. that & know about their role. Check lists & pinup boards prepared and displayed. Not more than 2 cases of Many instances of non non-maintenance. maintenance or lack of understanding. Hourly production is displayed. Status is updated as per required frequency. 2.5 1.For in use Tools/Equipments ownership is given. Everyone is aware about T5S Map and is followed habitually

12

T5S Map,Display No list prepared for areas of Checklist and List prepared and displayed requiring check lists & pinup pinup boardsand in identified areas. boards. production status No production status visually. Notice board control is poor. 1.50

100% adherence.

Prod. Status & loss can not be know. [5] 0.0

Status displayed and Prod. Status & loss under controlled. Problem is control. Consistent units connected to action and produced throughout the improvement. Action plans day. are prepared basis data. 3.75 5

13

Storage of Tools/Equipment s in use and not in use like jigs

1.In use Tools/Equipments 1.In use Tools/Equipments are not placed properly in are properly placed. working area. No cleaning & Identification given & clean identification. of oil, grease and grit. 2.Not in use Tools/Equipments are placed in working area. No one know what is lying and in what quantity. 0.0

1.In use Tools/Equipments 1.A location is defined for are having ownership sign proper working. stickers & in well condition.

2.Not in use 2.Not in use 2.Not in use Tools/Equipment are Tools/Equipments are Tools/Equipments are 2.A location is defined in placed in storage area for properly stored & clean of wrapped/covered properly store area for storing future further use in well oil, grease and grit placed & cleaned of oil, grease and used material. condition. Details of in working area. grit. material are known. 1.50 2.5 3.75 5

[5]

EESH CHECK LIST

Check points
1 Water Leakage 2.5 2

Level 1
More than 5 minor leakages

Level 2
4 minor leak points

Level 3
3 minor leak points

Level 4
2 minor leak points

Level 5
1. No Water leakage 2. Bonus= One water conservation innovation for saving water in the week.

E n e r g y

1.5
Equipment, Lights, fans & AC are found idlying at less than three area

2.5

Equipment, Lights, Equipment, Lights, fans & AC are found in fans & AC are found Electrical Gadgets idlying position in over idlying at more than five area. three area

All equipment, Lights All equipment, Lights & fans are in control & fans are in control with no wastage. with no wastage. High Medium awareness awareness level level

2
3 EHS Education & training 2 Innovations Energy Conservation (In last week) 2.5

0.75

1.5
Supervisors study EHS manual.

2
Awarness of EHS plan to superviser & operator

Supervisors are Just doing education. No EESH education & teaching EHS to their No practical training program. operators with experience. practical approach.

0.75
Selection of new ideas for power conservation

1.5

2
One innovation with investment & one without investment . Bonus : Two innovation for power conservation without investment

No Innovation

One innovation for power conservation

Two innovation for power conservation

E n v i r o n m e n t

1.5

2
Any three points below listed are Maintain for ( 100 % of the chemical ) 1. List of chemical, hazard labeling and max qty 2. SOP for storage & handling 3. Display of MSDS 4. Display of hazardous sign 5. Display of warning signs for hazardous chemicals (No unauthorised person) etc

2.5
All the chemicals identitified along with All points below listed are Maintain less than 100 % of the chemical . 1. List of chemical, hazard labeling and max qty 2. SOP for storage & handling 3. Display of MSDS 4. Display of hazardous sign 5. Display of warning signs for hazardous chemicals (No unauthorised person) etc

Any one points below ( Any Two ) below List of checmical not listed are Maintain( listed are Maintain for. identified along with Less Than 25 % ) of ( Less Than 75 % of below item. the chemical . the chemical ) 1. List of chemical, 1. List of chemical, 1. List of chemical, hazard labeling and hazard labeling and hazard labeling and max qty Chemical max qty max qty 2. SOP for storage & Management 2. SOP for storage & 2. SOP for storage & handling handling handling 1. List of Chemicals 3. Display of MSDS 3. Display of MSDS 3. Display of MSDS 2. MSDS 4. Display of 4. Display of 4. Display of 3. SOP hazardous sign hazardous sign hazardous sign 5. Display of warning 5. Display of warning 5. Display of warning signs for hazardous signs for hazardous signs for hazardous chemicals (No chemicals (No chemicals (No unauthorised person) unauthorised person) unauthorised person) etc etc etc

0.75

1.5

Pollution & Waste Management

None of the Pollution One of the Pollution Two of the Pollution Three of the Pollution All of the Pollution control equipment control equipment control equipment control equipment control equipment identified & in proper identified & in proper identified & in proper identified & in proper identified & in proper functioning functioning functioning functioning functioning 1.Air pollution 1.No air pollution 1.No air pollution 1.No air pollution 1.No air pollution 2. Noise pollution 2.No noise pollution 2.No noise pollution 2.No noise pollution 2.No noise pollution 3. Land Contaminations 3. No land 3. No land 3. No land 3. No land 4.No Proper storage Contaminations Contaminations Contaminations Contaminations with identification 4.Proper storage with 4.Proper storage with 4.Proper storage with 4.Proper storage with system for scrap 5.No identification system for identification system for identification system for identification system for Proper visulization scrap 5.Proper scrap 5.Proper scrap 5.Proper scrap 5.Proper visulization visulization visulization visulization

0.75

1.5

PPE (Usage & Condition)

S a f e t y

None of the activity are Any one activity are Any two activity are Any three activity are All the activity are managed managed 1.WI managed 1.WI mention managed managed 1.WI doesnot mention doesnot mention about about usage of PPE. 1.WI mention about usage 1.WI mention about usage about usage of PPE . usgae of PPE. 2. List of PPE's displayed of PPE. of PPE. 2. List of PPE's displayed 2. List of PPE's displayed at the Board 2. List of PPE's displayed 2. List of PPE's displayed at the Board at the Board 3. Operator aware about at the Board at the Board 3. Operator aware about 3. Operator aware about do & don't of PPE 3. Operator aware about 3. Operator aware about do & don't of PPE do & don't of PPE do & don't of PPE do & don't of PPE

2.5

0
1. No one is aware of evacuation route 2. Evacuation plan not displayed at proper location.

1.5

2.5

Emergency Evacuation Plan 2

1. 85 % peoples are 1. 90 % peoples are 1. 90 % peoples are 1. 100 % peoples are aware of the exit route in aware of the exit route in aware of the exit route in aware of the exit route in case of emergency case of emergency case of emergency case of emergency evacuation plan evacuation plan evacuation plan evacuation plan. 2. Evacuation plan not 2. Evacuation plan 2. Evacuation plan 2. Evacuation plan displayed at proper displayed at proper displayed at proper displayed at proper location. location. location. location.

0.75

1.5

Fire Equipment Management

None of the list of No List of following items List of following items List of following items with List of following items with following items with display : display withoout proper locations and qty. and locations and qty. and locations: 1. Fire Extinguishers details: proper display : proper display : 1. Fire Extinguishers 2. Fire Buckets. 1. Fire Extinguishers 1. Fire Extinguishers 1. Fire Extinguishers 2. Fire Buckets 3. Blockage of way to 2. Fire Buckets. 2. Fire Buckets. 2. Fire Buckets. 3. Blockage of way to reach Fire Fighting 3. Blockage of way to 3. Blockage of way to 3. All Fire Fighting reach Fire Fighting equipment easy to reach reach Fire Fighting reach Fire Fighting equipment easy to reach equipment easy to reach from all locations. equipment easy to reach equipment easy to reach from all locations. from all locations. from all locations. from all locations.

2.5 Emergency Team Fire Marshal and safety council Member. 5

1.5

2.5

10

No emergency Team 1.2 % of fire marshal of 1.5 % of fire marshal of 1.7 % of fire marshal of 1.10 % of fire marshal of 1. No fire Marshal are total employee. total employee. total employee. total employee. availbale in all shift . 2. 25 % training to fire 2. 50 % training to fire 2. 75 % training to fire 2. 100 % training to fire 3. No training from last six marshal 4.List Of marshal 3.List Of fire marshal 4.List Of fire marshal 4.List Of fire month. fire marshal display 5.No marshal not display 4.No marshal not display 5.No marshal not display 5.No 4.List Of fire marshal not identification of fire identification of fire identification of fire identification of fire display 5.No identification marshal. marshal. marshal. marshal. of fire marshal.

1.5

2.5

3.75

11

H E A L T H

None of the following items are maintained 1.Guarding at critical locations 2. Emergency Stop Workplace well located for Management & easy reach and safety Instruction clear visibility. 3.None of the safety instruction displayed. 4.Walk way not blockage

One of the Two of the following items are following items are not maintained not maintained 1.Guarding at 1.Guarding at critical locations critical locations 2. Emergency Stop 2. Emergency Stop well located for well located for easy reach and easy reach and clear visibility. clear visibility. 3.safety instruction 3.safety instruction displayed but displayed but operator not aware. operator not aware. 4.Walk way not 4.Walk way not blockage blockage

Three of the All of the following following items are items are not maintained maintained 1.Guarding at 1.Guarding at critical locations critical locations 2. Emergency Stop 2. Emergency Stop well located for well located for easy reach and easy reach and clear visibility. clear visibility. 3.safety instruction 3.safety instruction displayed & displayed & operator aware. operator aware. 4.Walk way not 4.Walk way not blockage blockage

2.5

1.5

2.5

12

None of the One of the Two of the Three of the All of the following following items are following items are following items are following items are items are maintained maintained maintained maintained maintained 1. All person known 1. All person known 1. All person known 1. All person known 1. All person known about the location about the location about the location about the location about the location of first aid box. of first aid box. of first aid box. of first aid box. of first aid box. 2.Availibility of 2.Availibility of 2.Availibility of 2.Availibility of 2.Availibility of First Aid medicine as per medicine as per medicine as per medicine as per medicine as per (First Aid Box + list. list. list. list. list. Stretcher) 3.Availibility of 3.Availibility of 3.Availibility of 3.Availibility of 3.Availibility of stretcher stretcher stretcher stretcher stretcher 4.Medical check up 4.Medical check up 4.Medical check up 4.Medical check up 4.Medical check up of employees of employees of employees of employees of employees working in working in working in working in working in hazardous area hazardous area hazardous area hazardous area hazardous area once in a year. once in a year. once in a year. once in a year. once in a year.

2.5

1.5

2.5

Quality POLICY
We are committed to manufacture and deliver quality products efficiency in a professional and flexible environment on time and at the right cost to our customer, while driving to become a world class organization .