Store Cleanliness and Maintenance Standards

KEY 5S AUDIT POINTS AND AUDIT SHEET 1. Sort (Seiri) Identify Unnecessary Items: Separate items that are not required for current tasks. Red-tagging: Use red tags to mark and remove unnecessary items. Free Up Space: Clear clutter and create a clean workspace. Minimize Waste: Reduce excess inventory and non-essential materials. Simplify Work Areas: Ensure only essential tools and equipment are present. 2. Set in Order (Seiton) Organize Tools and Materials: Arrange items in a logical order based on usage frequency. Label Items Clearly: Use labels or color codes to make identification easier. Create Storage Locations: Assign specific places for each item to reduce searching. Visual Controls: Implement visual cues like shadow boards to guide proper storage. Optimize Workflow: Design the workspace for maximum efficiency and minimal movement. 3. Shine (Seiso) Regular Cleaning: Perform daily cleaning of the work environment, machines, and equipment. Inspect Equipment: Look for signs of wear, damage, or malfunction during cleaning. Maintain Cleanliness: Keep floors, tools, and surfaces tidy to avoid contamination. Eliminate Dirt and Debris: Ensure all work areas are free from dust and waste materials. Preventive Maintenance: Develop a routine for maintaining and cleaning machinery to avoid breakdowns. 4. Standardize (Seiketsu) Create SOPs (Standard Operating Procedures): Develop written procedures to standardize tasks. Implement Visual Cues: Use color codes, labels, and signs for consistency. Ensure Consistency: Make sure practices are uniform across shifts and teams. Documentation: Keep records of standards to track adherence. Training and Awareness: Ensure all employees are trained on standardized procedures. 5. Sustain (Shitsuke) Develop Discipline: Foster a culture of self-discipline to maintain 5S practices. Regular Audits: Conduct routine audits to ensure 5S principles are followed. Continuous Improvement: Encourage feedback and constant updates to the 5S system. Management Commitment: Ensure leadership supports and promotes 5S initiatives. Employee Engagement: Involve employees in maintaining and improving 5S practices.

6S Audit Check Sheet 🎯 6S is a structured methodology for workplace organization and visual control, evolving from the original 5S system with Safety as the 6th element. Here’s what each "S" stands for: 1️⃣ Sort – Remove what's not needed 2️⃣ Set in Order – Arrange items for ease of access 3️⃣ Shine – Keep everything clean and well-maintained 4️⃣ Standardize – Ensure consistent processes across the board 5️⃣ Sustain – Maintain improvements through culture and habit 6️⃣ Safety – Proactively manage risks and ensure safe working conditions 🔎 Key Audit Checkpoints & Why They Matter ❶ 1S - Sort ✅ Only the required parts, materials, and stock are present ✅ Only essential tools and equipment are available ✅ Only necessary paperwork/signage is in the work area ✅ Unnecessary furniture, shelves, or clutter are removed Why?- Clutter-free spaces reduce errors, save time, and eliminate safety hazards. ❷ 2S - Set in Order ✅ Clearly labeled storage for parts, WIP, and stock ✅ Properly labeled tools with defined storage locations ✅ Labeled and accessible paperwork areas ✅ Marked walkways, access paths, and defined work zones Why?- Visual control ensures that everything is easy to find, reducing delays and confusion. ❸ 3S - Shine ✅ Tools and equipment are clean, damage-free, and maintained ✅ Work surfaces are clean and undamaged ✅ Walls and partitions are tidy and free of excessive signage ✅ Waste (swarf, oil, rubbish) is routinely cleaned ✅ Storage areas are clean and in good condition Why?- A clean workplace is easier to inspect, safer to work in, and extends the life of equipment. ❹ 4S - Standardize ✅ Up-to-date KPIs are visible and relevant ✅ Maintenance records are clearly available and current ✅ Work instructions and acceptance criteria are correct and accessible Why?- Consistency prevents variation, promotes quality, and ensures clarity for all. ❺ 5S - Sustain ✅ The 6S audit is visible, current, and shared ✅ Teams are recognized for participation in 6S ✅ Resources and time are consistently allocated for 6S ✅ Previous audit findings have been addressed and improved Why?- Without sustaining the effort, the benefits of 6S fade quickly. This step ensures it's embedded into culture. ❻ 6S - Safety ✅ Walkways and access to safety equipment are clear and identified ✅ The environment is suitable (lighting, air, temperature) ✅ Correct tools and equipment are available for tasks ✅ PPE, parts, and tools are stored safely and properly ✅ Staff are wearing appropriate PPE for tasks Why?- Safety is foundational. It protects people, productivity, and reputation. 📣 Let’s exchange ideas and raise the standard—together. 👇 ====== 🔔 Consider following me at Govind Tiwari,PhD. #6S #LeanManufacturing #OperationalExcellence #SafetyFirst #WorkplaceOrganization #ContinuousImprovement #Leadership #QualityCulture #Teamwork #AuditExcellence

The term 5S can be thrown around lightly these days and when we say 5S what do we really mean? Many companies are in a constant state of chaos, including the organisation and visual control of the process. Good housekeeping is seen as a negotiable - or an only when required (things get really out of control or we have an important visitor) and we go through a vicious cycle of tidy to mess over the proceeding days, weeks and months. There are a few reasons for this,however the antidote to this situation is firstly to standardise and maintain a realistic standard on a daily basis. Once the hard work of Sort, Set & Shine has been undertaken it is critical to set and capture a realistic standard that can be maintained on a regular basis by the team. What this looks like: ✅ Visual standard (picture) in area ✅ At minimum a Daily checklist with tasks and accountability ✅ Time allocated to maintain the standard ✅ Appropriate tools and equipment available for cleaning ✅ People that work in the area have ownership over setting the standard 😁 Once in place we can then move into auditing and Sustain. For me it is good practice to initially audit with the team to guide the process improvement. #chaostocalm #lean #humility

A clean and organized distribution center (DC) is not just visually appealing but also essential for efficiency and safety. While technological advancements are crucial, prioritizing security is paramount. Take a moment to ensure that your scrap materials like pallets, film, cartons, and garbage are well managed. Focus on the principles of reduction, recycling, reuse, and repurposing before discarding them. - **Pallet Management**: Pallets are significant assets in your DC. Aim to reduce scrap pallets by reusing supports, establishing clear pallet requirements with suppliers, implementing a pallet exchange program, or exploring other innovative initiatives. - **Carton Optimization**: Cartons are ubiquitous in your DC. Consider reducing consumption, opting for recycled cartons, utilizing plastic reusable containers, or other sustainable practices to minimize waste. - **Film and Plastic Recycling**: Ensure proper collection and recycling of films, plastics, straps, and other materials to contribute to environmental sustainability. - **Warehouse Cleanliness**: Maintaining a clean warehouse is crucial for ensuring the safety and efficiency of your operations. A clutter-free environment enhances productivity and minimizes risks. Remember, while automation and robotics offer exciting possibilities, establishing a culture of cleanliness and efficiency should take precedence. Invest in creating a clean and lean operational environment before delving into high-tech solutions. Prioritizing these foundational practices lays a robust groundwork for a successful and sustainable DC operation.