XX CELL
GUIDELINES FOR STANARDIZING AND SUSTAINING ‘5S’
SORT
(Do we need this?)
SET
(Do we have a good place for this?)
SHINE
(Is it in the designated place, labeled and clean?)
STANDARIZE
(Is there a written procedure for this?)
SUSTAIN
(Are we auditing and maintaining the written standard?)
Page 1 of 14
TABLE OF CONTENTS
GENERAL
 General Guidelines
 Area Division
 Daily Activities
 Weekly Activities
 Audits
 Floor Taping
 Floors, Wall, Aisles, Ceilings
Pages 3-4
MAIN CELL
 Cell Operation Areas
 Kanban and Queue Locations
 Supermarket
 SFGI and SFGI Overflow
 Communication Areas
Pages 5 - 6
TECHNICIAN AREA
 Troubleshooting and Repair
 Troubleshooting Test Fixture Storage
 Tool and Misc. Equipment Storage
Page 7
ADMIN AND MATERIAL SUPPORT
 Desk Areas
 Quarantine
 Staging area
 Reject Area
Pages 8-10
SECTIONS TO BE DEVELOPED
 Annex
 NPI cell
N/A
Appendix:
 Floor Taping Guidelines
 5S Operator Daily Check Sheet
 5S Audit Sheet - General
Page 11
Page 2 of 14
XX CELL - GENERAL

The guidelines for 5S in each area of the Signal Sources cell will be maintained
in a clearly labeled binder at the cell leader bench.

Any employee may suggest updates to the documentation.

Cell leaders and managers are responsible for maintaining updates. Only the
current approved version will be stored in the binder and this will be the only
authorized copy for setting the 5S expectations within the area.
The Signal Sources area of responsibility is divided into separate locations for the
purposes of conducting 5S activities. These areas are:
1. The Cell Operation area (cell “proper”). It includes the Supermarket as well as
operations on the main route from board test though shipping. Also included
are the communication (stand-up) areas, shift report and SQDC/QDIL board
content.
2. Troubleshooting and Repair area. This includes technician benches and the
storage locations within this area. Also included is test fixture storage, and
board repair benches.
3. Administration Areas: This includes manager, cell lead and material handler
desks as well as the staging, quarantine and rejects storage areas controlled
and managed by these individuals.
4. Annex and NPI lab:
DAILY ACTIVITIES:
Each operator, technician, material handler and manager will conduct a 5S audit of
their individual work area at the end of each shift. All tools will be verified and left
in the appropriate positions. Work surfaces will be clean. Floors will be free of
debris. Any unnecessary items will be removed. Trashcans will be emptied.
Calibration dates will be verified.
WEEKLY ACTIVITIES:
All employees will participate in weekly audits and corrections to findings during
the audits.
Page 3 of 14
AUDITS:
Audits will be conducted by each shift on a weekly basis at the end of the shift.
Results will be posted on the SQDC/QDIL board. “Outside” audits will be
conducted at least once per quarter by an individual who has been trained to do so
from any other group or support function.
FLOOR TAPING:
Refer to the reference sheet titled Level 3: Visual Controls – Floor Taping at the
end of this document.
FLOORS:
Floors are to be kept free of debris. Normal scuff marks are the responsibility of
the weekly cleaning service but any lack of service should be called to the
attention of the cell manager and the site manager for Washington Group.
WALLS and VERTICAL SURFACES:
Building walls and cubicle may be used as approved by managers to display
information, posters and pictures relevant to our business, events or current
information.
AISLES:
Aisle ways will be kept clear at all times even if a manager has authorized
temporary overflow. Trip hazards and obstacles to safe exit from the area are to
be avoided at all times.
CEILNGS:
Ceiling tiles should be free of obvious stains, breaks or holes. Burned out bulbs
should be brought to the attention of Washington Group for maintenance. Note
that some areas have bulbs removed with management approval
Page 4 of 14
XX – MAIN CELL
CELL OPERATION AREAS











Each work bench will use shadow boards for tools or have taped out space for
items that belong on horizontal surfaces.
Benches and PC’s should be regularly cleaned.
Cords and cables should be neatly dressed or stored and off the floor.
Work Instructions are posted on the company web site and will be open and
used for each build sequence.
Clipboards will be hanging at each station for displaying current waivers and
bench inventory sheets)
Kanban disciplines are TBD.
Only necessary items are to be present. Necessary items are to be clearly
labeled. All necessary items present and in their proper location at end of shift.
All equipment has current calibration dates.
No trip hazards
At no time should food items be found within the ESD protected cell area.
The stand up area should be free of chairs, instruments and material other than
what is needed for “show-and-tell”.
KANBAN AND QUEUE LOCATIONS
 TBD
Page 5 of 14
SUPERMARKET:





Flow Racks should be clean, labeled and orderly.
All part locations for storage are to be marked on both the front and back of
flow racks.
All individual boxes and totes are to be labeled with the current part numbers
(no use of –xx suffix).
Water skipper carts are to be left in taped out locations except when in use.
Personal notes, etc. are allowed on the work surface of the cart or pc location
during the shift but must be removed at the end of each shift.
SFGI and SFGI OVERFLOW:
 Instruments will be placed on the approved storage racks/locations in an orderly
fashion.
Page 6 of 14
XX Cell – TECHNICIAN AREA
TROUBLESHOOTING AND REPAIR
Technician bench tops and shelves are for tools, equipment and reference
material to be shared by bench partners. Items on the bench top and shelves will
be neatly organized and clearly labeled. The only items to be stored at the bench
are those items which are used frequently throughout the week.
Items used less frequently than on a weekly basis but are still needed for current
work activities will be stored in the storage cabinet. All items in this cabinet will
have a designated and neatly labeled location for storage.
The top bench drawer should contain shadow boards for tools. The bottom drawer
will contain neatly stored and organized reference material such as personal
copies of schematics or personal notes and other reference materials.
TROUBLESHOOTING TEST FIXTURE STORAGE:
 Each fixture is to be labeled with name or part number.
 Fixtures are to be stored in designated locations or taped out floor locations
when not in use.
 As fixtures are needed they are moved to a work bench. They are to be
returned to storage at the end of the shift or when finished working with them.
TOOL and MISC EQUIPMENT STORAGE:
Items infrequently used and shared by technicians will be kept in a storage cabinet
adjacent to the test fixture storage. Items in the cabinet will be neatly labeled and
stored.
Page 7 of 14
XX Cell
ADMINISTRATIVE AND MATERIAL SUPPORT AREAS
The purpose for these standards is two-fold:
1. Desk areas should be kept visually appropriate for tours, important customers
and other visitors.
2. In the event of an unplanned absence, the desk area should be organized and
labeled well enough to allow a person with general knowledge of the role to
take over with a minimum of difficulty in understanding what stage various
tasks were left in and where necessary records are stored.
ADMINISTRATIVE DESK AREAS:
 Administrative desk areas should be neat, well-organized and free of clutter at
the end of each work shift.
 Nothing shall extend above the height of higher cube walls.
 Work surfaces shall be clean of stains and debris.
 Drink and food items and containers should be properly stored away in the
break area, personal lockers or designated drawer space at the end of each
shift.
 No appliances (coffee pots, microwaves, refrigerators, etc.)
 Desks which are not shared with others are allowed personal items so long as
they do not impede on required workspace if others need to use the desk.
 Personal items should be appropriate to a business environment.
 Floors should be clear of items other than trash can, one recycle box and
personal heaters or fans approved by managers.
 Miscellaneous supplies should be neatly stored in pencil and desk drawers.
 Only currently active work should exist on the desktop.
 Cabinet surfaces should not be used for desktop overflow but may be labeled
and used for appropriate holding space for work.
 Drawers, cabinets and work in progress should be labeled well enough for
others to step in during an absence.
 Reference material posted on interior walls should be current and necessary.
 All parts and assemblies temporarily at a desk will be properly protected. They
will be re-located to their proper storage locations before the end of the shift.
Exceptions are allowed only for overnight attention and communication to the
next day’s shift.
Page 8 of 14
QUARANTINE:
The quarantine area is used to temporarily store material or instruments being
evaluated or with some kind of problem causing it need to be kept apart from
supermarket inventory. Items kept in this area must be labeled with the following
information:
 What it is
 Why it is in quarantine
 Who is responsible or owns the items/problem
 Date the item went into quarantine and if known, how long it is expected to be
stored there.
Items in the area should be reviewed at least on a monthly basis to be sure they
do not linger for long periods of time without action.
STAGING AREA:
Items in the staging area are instruments staged for work activities that are not
part of the cell daily rate or are waiting for some support activity. Examples are:
 Code 5 warehouse returns
 Waiting for rework
 Production Hold.
As items move into the staging area the white board will be updated with the
following information:




Date in
Who is responsible
Reason for the item being in the staging area
What needs to happen for it to move out and/or expected date for it to move
out
As items leave the staging area they should be erased from the white board so
that the white board is always up-to-date with the current content of the staging
area. This area should be audited as part of the end of shift clean up activities
each work day.
This is not a location for storing parts or collecting unnecessary items.
Page 9 of 14
REJECT AREA:
Reject parts must be clearly labeled and should be found in only one of three
areas:
1. Cell lead desk tops have clearly marked bins for parts coming off the line as
material needing to be rejected. Cell leaders print the appropriate tags and do
all necessary quality record entries. This work should generally be completed
before leaving for the day.
2. Once rejects have been appropriately labeled and transacted by the cell lead,
they are moved to the black bins on the reject carts adjacent to the staging
area. Material Handlers process these items on a daily basis by transacting
them in Oracle. As they do so, the material is moved to the orange bins for an
engineering review prior to having the parts scrapped. Engineers will make the
final determinations as to whether these parts can be used “as is”, returned to
vendors or discarded as scrap.
3. Cell lead benches also have separate bins for returning reject parts to each
shift cell leader when the reject tags have not been properly filled out. This
ensures the correct individual gets the appropriate feedback for corrective
action in the future. These bins are not to be used to deposit reject parts for
any other reason.
No part should linger in any one location for more than two business days.
Exceptions should be brought to the shift managers attention so that additional
help can be called for as needed. Rejecting parts in a timely manner ensures we
can keep appropriate inventory levels and have knowledge about leading edge
quality problems.
Page 10 of 14
APPENDIX



Floor Taping Guidelines………………………….Page 12
5S Operator Daily Check List…………………….Page 13
5S Audit Sheet – General…………………………Page 14
Page 11 of 14
Page 12 of 14
Page 13 of 14
Page 14 of 14