5S & Visual Management

December 2002
5Cs and
Visual
Management
5C (AIRBUS\APS\WORK PLACE MGT\5C Training ISSUE 01)
Contents
Introduction / APS Framework
5C Overview / Getting Started
Clear Out & Classify
AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.
Configure
Clean & Check
Conformity
Custom & Practice
Quote.
Make your workplace into a showcase that can

easily be understood by anyone at a glance.
In terms of Quality, it means to make
defects immediately apparent. In terms of
Quantity, it means that progress or delay,
measured against the plan, is made immediately
apparent.
When this is done, problems can be
discovered immediately and everyone can initiate
improvement plans.
What do you
see?
- Taiichi Ohno
The Visual Management Overview
Definition: Implementation of systems

that bring knowledge to the working
environment, enabling employees to
differentiate between the normal, and
abnormal IMMEDIATLEY
Illustration from The Visual Factory - Grief
The status of the business is communicated to the employees

The process becomes TRANSPARENT we learn to SEE
If we have the ability to SEE, we have the potential to CONTROL
If we can CONTROL the business, the result is PERFORMANCE
Through this transparency, we can identify problems and eliminate WASTE
Hierarchy
5C
Clear & Classify, Configure, Clean & Check, Conformity, Custom & Practise
Visual Management The Benefits

Large return on minimal investment
Significant initial step in making the transition to a Lean Manufacturing
environment
Introduces the workforce, and Leadership, to STANDARDS

Challenges the DISCIPLINE within the organisation
Develops the knowledge THROUGH the organisation, which gives us the
POTENTIAL to Involve ALL levels in performance improvement
Sets the foundation for the development of our operating CULTURE
WELCOME
TO OUR
VI SUAL
FACTORY
December 2002
5C Overview / Getting Started
5C (AIRBUS\APS\WORK PLACE MGT\5C Training ISSUE 01)
5C Overview
There are no world class manufacturing companies without 5C in place
There are many sub standard companies with good house keeping
The 5C Approach
5C is a systematic approach to workplace organisation, encouraging
ownership and self discipline to sustain and further develop working
practices.
It aims to :-
Remove waste from the workplace.

Provide an environment where continuous improvement is
embraced.
Improve safety.
Increase quality.
Identify abnormalities immediately (deviation)
Eliminate FOD.
The 5Cs
The C are five words, which provide the steps to improvement:
Custom & Practice

Conformity
Clean and Check
Configure
Clearout and
Classify
1st Step - Clear Out and Classify

Conduct major clean-down.
Remove all items that are not required or have become
unnecessary over a period of time. (Refer to red tag process)

Includes identifying broken tools & equipment.
Frequently used items should be stored at the work area.
Infrequent used items stored away from the work area and dispose
of items that are not needed.
Never assume. Ensure everyone is in agreement.
.Remember! Redundant items cost money to
store - If you dont need it, dont keep it!
Items not needed should be placed

in stage red tag area
Items not needed should

be disposed of
Items that are needed should be

stored correctly and in the right place
Classify
Classify tooling / equipment by frequency of use
Code
HIGH
MEDIUM
LOW
Description
Hourly
Daily/Weekly
Quarterly/6 Monthly
Action
Keep at
workplace
Store at
dept store
Store away
from area
or dispose
.within the LOW category, retrieval MUST still be quick!!
Red Tag Strategy

This means putting red tags on any items not required for the current
production, any items kept in excessive amounts and any items used
infrequently. Then removing these items from the area/cell.
Tooling Collected during red tag
General Waste Collected during red tag
Scrap / redundant tooling must be disposed of using ME-PROC-08-059

procedure. Contact your local tooling engineer for advice if needed.
5C Overview
The 5Cs
The C are five words, which provide the steps to improvement:
Custom & Practice

Conformity
Clean and Check
Configure
Clearout and
Classify
1st Step - Clear Out and Classify
Red Tag Example

WEST FACTORY 5C RED TAG
STAGE 0
STAGE
ITEM NAME
Leading Edge Drill Jig
QUANTITY
3 off
WHERE FOUND
Bay 2 O/B T/E
ORIGINATOR
Jim Smith
DATE
26 MAY 2004
STAGE 3
P/L
Why Clear Out & Classify ?
Frees up space.
Removes clutter/obstacles.
Stops people adding to it.
Stops hoarding.
Improves safety.
Gives control of what is in your area.
Begins the orderliness process.
2nd Step - Configure

To arrange all necessary items for economy of movement.
Place according to frequency of use.
To have a designated place for everything to label, classify and make
easily visible.
A place for everything and everything in its place.
Provide safe storage - heavy items low, light items high.
Configure Examples
Footprinted areas (With labels)
Shadow Boards
Labelled racking
Configured Parts / AGS
Improves safety.
Frees up space.
Removes clutter/obstacles.
Stops people adding to it.
Stops hoarding.
Gives control of what is in your area.
Begins the standardisation.
Configure Examples
A place for everything and everything in its place
Why Configure ?
Makes things easier to find, use and return.

Removes frustration of searching for items.
Creates a better working environment.
Reduces accidents.
Assists cleanliness.
Begins standardisation.
3rd Step - Clean & Check
Identify Cleaning Zones.

It is everybodys responsibility.
Set targets and work to them.
Keep your area clean and tidy on a continual basis.
Cleanliness extends to non-seen areas
(eg under the jig!, behind cupboards etc).
Routine maintenance may be incorporated (TPM).
Clean & Check
Can be divided into 3 sections :-
Overall
Situation
Major cleaning operations and

plan to find sources of dirt.
Individual
Situation
Cleaning workplace and

all equipment.
Detailed
Situation
Preventing defects by cleaning &

checking machines, jigs and
tools (Equipment 5C).
..Creating a spotless workplace
Identifies specific cleaning & checking operations

TPM CHECK
SWARF IN TOOL CHANGER
ITEM HENRI LINE MCC 22

REF
Check tool changer to see if

any swarf has collected where
coolant feeds through. If so,
use air gun to clear any
blockages
Check machine top surfaces

and pedals to remove swarf
deposits
Dispose swarf in designated

place at the required intervals
Single Point Lessons

(inc Clean and Check)
TPM Check Sheets to maintain

and sustain the standard
..through cleaning you touch, through touching you find

when you find, you fix !!
Clean & Lubrication Sheet - Example

Date:
Process:
Machine: GEAR RIB PINTLE

WING REMOVAL
Cleaning Items
C
Item to Clean
LOCATING PINTLE
2
3
AREA AROUND SHAFT

SUPPORTING ACTUATOR SHAFT
GENERAL AREA
4
C1 + D1
Lubrication & Inspection Items

D
Item
LOCATING PINTLE - INSPECT FOR
WEAR, LUBE WHERE NECESSARY

SUPPORTING ACTUATOR SHAFT AS ABOVE
C3 + D2
3
REPORT ANY DAMAGE TO TEAM

LEADER
Why Clean & Check ?
Makes defects easier to detect.

Better customer perception.
Creates a better working environment.
Aids efficiency and reduces accidents.

Helps standardisation.
4th Step - Conformity
Use visual controls.

To maintain the workplace at a level which uncovers and makes
problems obvious.
To continuously improve by continuous assessment and
generating actions.
To include routine health and safety.
Safety
Highest quality
Lowest cost
Continuous Improvement
Human centered work
..the system must be controlled

and maintained (using agreed
standards.)
J ust
in
time
Built
in
Quality &
Safety
Problem solving
Standardisation & TPM
How can we conform ?

Tools:
The physical attributes of an effective communication structure at all levels within the
business:
Work group information centre

Daily review of SQCDP
Full group attendance
Management Information Centre

Full team attendance
Immediate reaction / support for issues
Team Boards
Full team attendance
Full team involvement
Conform
Visual Display:
a place for everything, everything in its place
Performance by Dept, area and team.
Status understood at a glance.
standard process method
problem status
manpower requirement
location / deployment
skill and versatility
planning / action status
reject, scrap and quarantine
real time status

actual vs target
minimum / maximum
Why Conformity ?
Provides schedule of 5C activities.
Ensures deterioration does not occur.
Gives a standard to work to.
Starts problem solving/improvement activities.

Safety
Highest quality
Lowest cost
Makes first 3Cs a habit.
Continuous Improvement
Promotes ownership.
Human centered work

J ust
in
time
Built
in
Quality &
Safety
Problem solving
Standardisation & TPM
5th Step - Custom & Practice
Probably the most difficult of the 5Cs.

Make it a habit.
Setting review frequency.
Cleaning checklist matrix.
To maintain our habit we need to practice and report until it
becomes a way of life.
Visual communication instead of verbal!
..Ownership !!
Without it the other steps will fail!
Area Process Confirmation

To be used by management to check standard adherence
Timely process confirmation in appropriate areas.
Process Confirmation
MONTH:__________
To Be Com ple te d
OK Condition
NG Condition
Wha t
How
APT proces s (Tgt 1 / Team / We ek )
Atte nd team APT m ee ting
10
11
12
13
14
15
16
PPE Adhe re ance
S
Q
Standar d Operating Ins truction - Confirm
Confir m oper ator se quence , ke y points
adher eance.
for H&S / Quality.
Revie w Pr oblem Solving A3
Confir m logic and 5 w hy. GLS containm ent.

Che ck Ope rators unde rstanding / CM
pr ogre ss .
Team cost tr acking
Confir m track ing up to date / w ithin

param e tre s.
Kaizen r evie w
Info ce ntre - team board - re vie w

im plem e nted w ith ope rator
Remember !
What you
see, you manage
D
P
Attend Pr e Shift Me eting
Leadership
Regularly review results, and feedback & communicate to all.

Create management shopfloor visibility, Walk the walk, talk the talk.
5C Summary
5C IS NOT HOUSEKEEPING, IT IS COMMUNICATION AND CONTROL
Improves safety.
A structured approach.
Applicable to the General Manager and everyone else.
Improves productivity.
Improves quality.
Improves morale and teamwork.
Enjoy - working in a clean, organised, quality,
successful, safe environment.

5S &amp; Visual Management

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December 2002

5C (AIRBUS\APS\WORK PLACE MGT\5C Training ISSUE 01)

Make your workplace into a showcase that can

The Visual Management Overview

Definition: Implementation of systems

Illustration from The Visual Factory - Grief

The status of the business is communicated to the employees

Visual Management The Benefits

Introduces the workforce, and Leadership, to STANDARDS

Sets the foundation for the development of our operating CULTURE

5C Overview / Getting Started

5C (AIRBUS\APS\WORK PLACE MGT\5C Training ISSUE 01)

There are no world class manufacturing companies without 5C in place

Remove waste from the workplace.

The C are five words, which provide the steps to improvement:

Custom & Practice

1st Step - Clear Out and Classify

unnecessary over a period of time. (Refer to red tag process)

Items not needed should be placed

Items not needed should

Items that are needed should be

.within the LOW category, retrieval MUST still be quick!!

Red Tag Strategy

Tooling Collected during red tag

General Waste Collected during red tag

Scrap / redundant tooling must be disposed of using ME-PROC-08-059

The C are five words, which provide the steps to improvement:

Custom & Practice

1st Step - Clear Out and Classify

Red Tag Example

Leading Edge Drill Jig

Bay 2 O/B T/E

Why Clear Out & Classify ?

2nd Step - Configure

Configured Parts / AGS

Makes things easier to find, use and return.

3rd Step - Clean & Check

Identify Cleaning Zones.

Clean & Check

Can be divided into 3 sections :-

Major cleaning operations and

Cleaning workplace and

Preventing defects by cleaning &

..Creating a spotless workplace

Identifies specific cleaning & checking operations

ITEM HENRI LINE MCC 22

Check tool changer to see if

Check machine top surfaces

Dispose swarf in designated

Single Point Lessons

TPM Check Sheets to maintain

..through cleaning you touch, through touching you find

Clean & Lubrication Sheet - Example

Machine: GEAR RIB PINTLE

AREA AROUND SHAFT

Lubrication & Inspection Items

LOCATING PINTLE - INSPECT FOR

WEAR, LUBE WHERE NECESSARY

REPORT ANY DAMAGE TO TEAM

Why Clean & Check ?

Makes defects easier to detect.

Aids efficiency and reduces accidents.

4th Step - Conformity

Use visual controls.

5S & Visual Management

5S & Visual Management