5S – Verification of Level

April 2018
• All EU plants
5S Level categorization
KEY ELEMENTS 2-1. System 2-2. Results 2-3. Culture

“DO THE 5S DAILY ACTIVITY” “ACHIEVE GOOD RESULTS” “INSTILL 5S INTO THE CULTURE”
• Zones defined for all areas, including office, external For whole plant: • Good 5S performance is formally recognized
areas, and warehouses • Average 5S score of 75% or higher (simple average of all • 5S included in new hire training
• RASIC defined zones) • Plant Manager performs regularly scheduled audits as part of the 5S
Bronze • Schedules created • For 2 consecutive months System RASIC
(mandatory) • Checksheets created • Plant Manager certifies Bronze achievement
• Metrics set up At this level, the plant is always ready for customer visits without
needing any special preparation.

“STANDARDIZE & IMPROVE PHYSICAL “DO BETTER” “PERIODICALLY REINFORCE”

APPEARANCE” For whole plant: • At least once per year, reinforce 5S culture with a specific activity (5S
Bronze level items plus: • Average 5S score of 85% or higher Focus Days, Presentations from Champions, Community service
Silver • Global Facility Standards implemented (simple average of all zones) involving 5S)
(optional) • Plant physical refreshment activities completed as • For 3 consecutive months • Regional Ops Director & external CI certify Silver achievement with
necessary audit

No additional items “BE THE BEST” “BE A GLOBAL LEADER”

For whole plant: • Plant Manager 5S cross-audit 1x/year
• Average 5S score of 95% or higher (can be part of OEA cross-audit)
(simple average of all zones) • Share and adopt formal 5S Best Practices
Gold (at least 1 share and 1 adopt)
• No individual zone less than 75%
(optional)
• For 4 consecutive months • Ops VP judges employee engagement in 5S
• Ops VP & external CI certify Gold achievement with audit

2
Tangier, Nawal
Verification – Zones defined for all areas

4
Verification – 5S Schedule

5
Verification – 5S Check-list

6
Iasi, Teodora & Mihaela
2.1 System
• 5S Management Commitment • Checksheets

Checklist 5S

• 5S Zones & Audit Schedules • Metrics

Plan audit si zone

8
2.2 Results
• Results tracker • 5S Board

5S results tracker

9
2.3 Culture
• 5S Visual management in Iasi Plant

Standardized visual management boards for 5S & 7 Wastes Boards 5S Steps Boards 5S Pillars
KPI and other departments information

10
2.3 Culture
• 5S Visual management in Iasi Plant

5S for document standardization – each

5S tool storage in Maintenance area department has different color for paper folders

H&S floor stickers 5S cleaning station Panel for keeping protective helmets Visual management panels above waste
and awareness board for wearing it segregation zones for encouraging
selective sorting of wastes.

11
2.3 Culture
• 5S Visual management in Iasi Plant

Wall posters in the area with OK –NOT OK

5S

5S Visual management: sad face – happy

face, red flag-green flag

12
2.3 Culture

• 5S Training
o All new employees (both hourly and salary) are trained regarding 5S system in their first week

o 5S training is provided as part of Line Leader’s school program

o Once per quarter 5S day is sustained in offices area and employee knowledge about 5S is
refreshed through a brief training
o Gemba walk two times a day with 5S points to check in each area

New employees 5S event - brief Give me 5 by 5S

5S training training event

13
2.3 Culture
• 5S Bronze Level Recertification – 2018

14
Jaroslaw, Marcin
Verification – Zones defined for all areas
• Plant divided into zones ( production and offices )
o Realization in two layers:
- Layer 1 – daily audit on first shift done by owner of area
- Layer 2 – weekly audit according to the agreed schedule

Tasks for realzation in TQMSystem for Layer 2 and Layer 1 Offices

Layer 2 for plant Layer 1 for offices Tasks in TQM

16
Verification – check lists ( weekly template )
Production areas

Offices

17
Verification – Results
• Weekly summary (results for each area and weekly total) and yearly summary (score of plant)

18
Verification – Top3 nonconformities
• Top3 of nonconformities from each month – tasks for improving activities in TQM for Production
Manager

19
Tetovo, Jana
Verification – Zones and Champions defined

21
Verification – Audit schedule plan
• Weekly
o Salaried (44 auditors, each person gets to audit different area every second week)

• Monthly
o Managers – twice per month

22
Verification – 5S Check-list (Global template)

23
Ungheni, TBD
Verification – Pics, Data etc.

25
Verification – Pics, Data etc.

26
Verification – Pics, Data etc.

27