5STraining Material.docx

1、5S Training Material一 5S的簡介(Introduction of 5S):1. 5S的定義(Definition of 5S):5S是指整理，整頓，清掃，清潔，紀律。日語的發音各為SEIRI，SEITON，SEISO，SEIKETSU，SHITSUKE，因其第1個字母都是S，因此簡稱”5S”。5S的定義如下:5S means distinguish, arranging, cleaning, keep clean, discipline respectively. In Japanese, they read as: seiri, seiton, seiso, seike

2、tsu, shitsuke respectively. Because they are all s-prefix, so Japanese call them “5S”. The definition of 5S is as bellow: (1) 整理(Distinguish):*分開需要與不需要的東西。Distinguish “useful” and “useless” things.*丟棄或適當處理不需要的東西。Discard or dispose useless things.*保管需要的東西。Safekeeping useful things.整理為5S的基礎，也是效率的第一步，先

3、清理不需要的東西，以騰出現場的作業空間，藉此塑造清爽的工程環境。由於先清理不需要的東西，可使員工不必每天反覆不需要的整頓及清掃工作。所以整理為5S的基礎，也是效率的第一步，其主要對象為空間運用的合理化。Distinguish is the basis of 5S, its also the first step of enhance efficiency. After disposing useless things, we can enlarge work space and make working environment more conformable. Since useless t

4、hings has been screened out, the operators dont need to arrange them again and again. So distinguish is the basis of 5S, the major target is “Reasonable using the work space”. (2) 整頓(Arrange):*將東西定位。Put things in specific location.*將東西標示。Marking the things.*將東西歸位。Put things in the right location.整頓為

5、東西放置的標準化，使人員在需要的時候，可以很快找到所需要的東西。整頓亦透過看板及標示的目視管理，如同超級市場一樣，不管是誰都能很快找到自己想要的東西。因此，整頓的最終目的為創造一目了然的工作環境，其主要對象為縮短物品的尋找時間。Arrangement means to standardize storage location of things, it will let everyone find anything which they need. There are 2 kinds of tools can be used to arrange things: “kan-ban” and “

6、marking”, its just like in supermarket, anyone can find they want by looking “kan-ban” and “marking”. So the major target of arrange is “Create a clear working environment”, then “shorten the time of looking for things”.(3) 清掃(Clean):*消除污垢。Eliminate dirty.*自主保養的第一步。Preventive maintain.員工透過清掃的行為，以早期發

7、現設備的異音，異溫，鬆動等，而達到全面生產保養的目的。因此，清掃的最終目的為創造高稼動率的工作場所，其主要對象為保持環境整潔及設備的高可靠度。Though the cleaning, we can find preliminary deviation of machine. This will let us finish the target of “total preventive maintenance”. So the major target of cleaning is “ Create high efficient working environment”, then “Keep

8、environment clean and with high reliability”. (4) 清潔(Keep clean):*維持整理，整頓，清掃的既有水準。Keep the effect of “distinguish”, “arrange”, and “clean”.*根絕髒亂源頭。Eradicate the root cause of dirty.徹查髒亂發生的源頭，並加以改善。例如在發現設備有異音，異溫，鬆動等現象時，即應找出異常之原因及預防再發的方法。因此，清潔應有追根究底的科學精神，其最終目的為創造明朗的工作場所。Find the root cause of dirty an

9、d improve it. For example, if someone find any deviation for machine, he should find out the root cause and take in preventive action. So “keep clean” means “science mind for solving problem”, and “to create a clear working environment”.(5) 紀律(Discipline):*養成守法精神。To obey the rule.*養成習慣。Make “obey ru

10、le” to a custom.透過不斷的教育訓練，獎勵措施及考核方式，使人員養成作業習慣。如此才能將良好的工作方式持續推展。待人員習慣於良好的作業習慣後，無論對產品品質或效率提升皆有很大的幫助。Though continuous training, award, and audit to form a habit. Let the good idea can be performed for long term. If everyone can get used to the habit, the quality productivity and efficiency will be gre

11、atly enhanced.2 5S可以節省生產成本嗎? (Can 5S reduce production cost?)在豐田生產方式中，指出生產現場的7項浪費如下:There are 7 types of waste in TOYOTA production method:*製造過多的浪費。Manufacture too many.*待工待料的浪費。Wait for material or machine.*搬運的浪費。Transportation. *加工本身的浪費。Unnecessary machining.*庫存的浪費。Stock.*動作的浪費。Unnecessary motion.

12、*製造不良的浪費。Defective product. 藉由5S的執行，對上述浪費的改善關係如下圖所示:The relationship between 5S and waste is as below table: 整理Distinguish整頓Arranging清掃Clean清潔Keep clean紀律Discipline製造過多Manufacture too many.待工待料Wait for material or machine.搬運Transportation.加工Unnecessary machining.庫存Stock.動作的浪費Unnecessary motion製造不良De

13、fective product.3 5S的其他效益 四 5S的實施工具紅牌作戰所謂的紅牌即是指紅色標籤或紙張，主要用於標示現場待整頓之物品。紅色標籤可使用於以下三類對象:Red sheet means that label or paper in red, the major function is to mark things which should be arranged. Red sheet is applied to 3 items as below:1. 庫存品: 材料，半成品，配件，成品。Stock: material, work in process, parts, finis

14、h good.2. 機器設備:生產設備，維修工具，維修備品。Equipment: machine, tool, spare parts.3. 空間: 地區，通道，架子。Space: area, aisle, cabinet.紅牌之決定基準可參照以下之標準:The following 3 conditions should be purged by red sheet.1. 超出期限者: 滯存原料，滯銷成品。Obsolete valid date: Idle material, idle finish goods.2. 物品變質者: 氧化，變質，受潮導致影響產品品質者。Deterioration

15、: Material which oxidized, deteriorated, wetted.3. 物品可疑者: 雖經數次活動，但物品仍保持原狀，未有使用跡象者。Skeptical things: The thing remains original status after several times of activities.五 導入5S之步驟*步驟一: 導入前之教育-以各部門主管及生產線領班為訓練種子，講授有關5S之定義及其必要性，以獲得共識與支持。*Step1: Training before implementation Train seeds who are departmen

16、t heads and shift leaders about 5S definition and why to implement 5S. *步驟二: 確立5S推行體制-成立委員會，透過組織的力量整合人力與資源，以使全員參加，藉此使活動活潑化及持續化。Organize promotion committee Recruit staff member to integrate manpower and resource. Make sure all people join this activity and keep this activity continued.*步驟三: 擬定5S推行計畫

17、: 包含年度活動計畫，預算及活動辦法。Draft 5S implementation plan: It includes annual plan, budget and implementing method.*步驟四: 公司內啟蒙教育: 以全體員工為對象，由內部種子人員進行傳達教育，負責講授5S之定義，推行要領等。Step4: Overall training Training all employee in company. Seeds are teachers who promote 5S definition, sprite and instruct the implementing

18、method.*步驟五: 正式發動。Step5: Implementation.*步驟六: 5S之評比及持續推行。Step6: Evaluation and audit for 5S.附件一 紅牌圖例 (Red Sheet)品名(Description):料號(P/N):數量(Qty):類別(Category):1. 原物料(Material) 4. 機械設備，備品(Machine, Parts)2. 在製品(WIP) 5. 治具，工具(Tools)3. 成品(Finish Goods) 6. 其他(Others) 待處理原因(Reason for disposition):1. 不需要(Us

19、eless) 4. 不明品(Dubious)2. 不良品(Fail parts) 5. 其他(Others)3. 呆料(Idle material)處理部門(Responsible Department):處理方式(Disposition):1. 丟棄(Discard) 3. 別的保管方式(Other safekeeping method)2. 移動至紅牌放置場(Move to specific place) 4. 其他(Others)附件二 5S稽核表稽核地點(Place of audit): CategoryNo.Audit Item是否備註整理(Distinguish)1要/不要的東西是

20、否區分?Separate useful/unuseful parts.2不要的東西是否已清除?Clean the unuseful parts.3不要的東西是否置於規定處?Unuseful parts should be put in specific area.4工作現場是否保持整潔?Work area should keep clean.整頓(Put thing in order)5物品品名是否標示清楚?Parts name should be show. 6物品數量是否標示清楚?Parts Qty should be show.7工作現場的物品是否定位整齊?All of the part

21、s in work area should be put in right location.8斑馬線之貼附是否完整?Zebra tape should be stuck on the ground completely.清掃(Clean)9地面上是否保持清潔?Keep floor clean.10機器設備是否保持清潔?Keep machine clean.11工作檯面是否保持清潔?Keep work plate clean.12是否定期清掃點檢設備?Clean and check machines periodically.清潔(Keep clean)13機器設備是否定期保養?Maintai

22、n machines periodically.14保養後之機器設備是否確實乾淨?Machines is really clean after maintain.15相同之髒亂是否連續兩天發生?Same contamination happened in continuous 2 days.16工作服是否保持整潔?Keep the ESD cloth clean.紀律(Discipline)17產品是否依照規範及程序生產?Follow specification and procedure to make products. 18作業時是否遵行ESD之規定?Follow ESD specification to work.19工作現場是否皆穿靜電服?Wear ESD cloth to wrok.20工作時是否不聊天?No chatting in work.稽核者(Auditor): 日期(Date): 班別(Shift):