5S STANDARDS

OPERATIONAL SYSTEMS DEPARTMENT

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 01. INTRODUCTION
When the lean process 5S is the key thing to the journey. Simply "5S", is a tool that based on structured
process system which systematically achieve the organizational cleanliness, and standardization of the
workplace.

Well maintained clean and organized workplace provides the results as safer, more efficient and more
productive than disorganize work place. It is the key fundamental thing that provides the productivity
through the 5S journey. Through this eliminate the waste and provide good quality product will be the
outcome of the journey of 5S.

A proper well-organized workplace helps towards a problem-solving culture through the free mind.

Thee requirement of the “5S Facilitator’s Guide” will be to conduct and provide the introduction and
implementation of one form of LEAN production philosophy at the Hirdaramani Knit Cluster.

DEPARTMENT & SUB-DEPARTMENT NAME BOARDS

1.1.1 Department Name Board

CUTTING
DEPARTMENT
20” * 12” (Or Multiples)

1.1.2 Sub-Department

18” * 6”

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 DOOR NAMING & OTHER SIGNAGE’S
1.2.1 Door Naming

GENERAL MANAGER

13” * 3”

1.2.2 Door Opening Direction

SLIDING DOOR

P P
U U
S L
H L
(If 2 Doors Are Present Then We Need to Place 4 Boards)

OPEN OPEN
(6” * 3”, Above Boards Use for Sliding Doors)

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1.2.3 Wash Room

6” * 6”

PLANT SITE MAP

Every building need to be included in the site map and deferent colors can be used for each building block
to identify the deferent buildings in the site as well as each building need to demarcate by a number. Pease
refer the attached site Map (01) for your reference.

• Placement: - Entrance of each factory

• Nature: - Digital Sticker with iron Frame.
• Size:- Vary, depending on the Plant

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 DIRECTIONAL BOARDS
1.4.1 Main Direction Board

• Place at outside the factory in appropriate places. (Close to the entrance, and every road junction).
• The board is fixed to the ground with a metal stand.
• Display board height - Can be vary according to no of directions
• Display board width - 2.5 feet
• Font - Arial
• Color - Navy Blue Back Ground, White Font
• Method - Laminated Sticker Print pasted on Amano Sheet, and 1-inch Box bar
frame with roof

1.4.2 Internal Direction Board

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• Hang on the appropriated places 2m above from the floor level. (inside junctions),
• Display board height - 3 inch (Each Square)
• Display board width - 18-inch max
• Font - Arial
• Color - Navy Blue Back Ground, White Font
• Method - Printed Sticker cut and paste Plastic Sheet

EVACUATION MAP

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 PATHWAY ARROWS DEMARCATION

1.6.1 Background
• Color = Green
• Size = Length 12”; Width 08” 2”

1.6.2 Arrow
• Color = White
• Size = Length 08”; Width 04”

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 GRID REFERENCE FOR BUILDINGS

Gird Reference

Gable
Trusses

Grid reference is used to identify the location inside a factory or a large building.
Building can be divided in to two main parts.
o Gable
o Trusses

A. Naming Gable’s side

1. Find the center of the of the gable’s side.
2. Divide gable in to two main parts.
3. Divide equally those two main parts in to small parts.
4. Name it as below by using English alphabet.
5. Naming should be left to right of the gable

C D

A F

Gable Side

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A. Naming Trusses side
1. Divide trusses side in to similar small parts. (Can be used iron columns in the building)
2. Name those small parts from left to right by using numerical numbering system as 1, 2, 3 ….

1 2 3 4 5 6

Trusses
All four insides of the building should be indicated with Grid reference.
Required only to identify grid lines inside the buildings (No long lines)

Name and Numbering Boards

It should be A4 paper size and orientation should be landscape

Font – Arial and should be centered to the paper
Font Color- Red with black out line
Back ground – White
Border of the paper- Black normal out line

30cm 30cm

21cm 21cm

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Example:-

TELEPHONE DIRECTORY

(Attached to The Phone Wire Cable)

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 NOTICE BOARD
1.9.1 Standard Sizes
Length (feet) Width
(feet)
8 4

6 4

4 3

1.9.2 Display Board

(Size: - 15” * 3”)

1.9.3 Material

Material Size Cost

Plywood Board 8ft * 4ft Rs.2850.00
Melamine 8ft * 4ft Rs.3000.00

Note:

• Plywood Board does not consist with a standard color; therefore, we should paste
Formica sheet for that.
• But in Melamine, it comes with 03 colors, we do not want paste anything on that.

1.9.4 Placement Height

1.5ft from the floor level

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1.9.5 Numbering

Size: - (7’ X 3’)

HR 01 HKEH 01

Department Notice Boards Common Notice Boards

1.9.6 Other Department 5S Sub Committee 3W Board

Material: - Clear sheet, screw, and hard board

Dimensions: - Clear Sheet Length 45cm width 33cm; Hard board Length 46 width 36

ELECTRICAL PANEL DEMARCATION

Main electrical and sub panel boards in the institution identifiable and indicated on the front panel door.

2 Inches Tape should paste on the panel board covering the edge as per the below pictures.

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Side view of panel (Marking need to be visualized from the angle)

Front View

TROLLEY PARKING AREA DEMARCATION

• Width of the tape = 2 inches

• Color = Golden yellow

Should be parallel or perpendicular to the wall (X and Y Axis alignment) where it is possible.

No space allowed between two consecutive parking slots.

Size depend on the trolley size.

Single parking slot (this is sample only shape and size may vary according to the requirement)

Few Parking Slots Together (this is sample only shape and size may vary according to the requirement)

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Pathway should mark with 4” dash line in front of trolley parking area as per the below picture.

DANGER/ CAUTION AREA DEMARCATION

Yellow and black tiger marks need to paint or paste (2” width tapes/sticker) where it is required.

E.g. Manholes at pathways, Beams at pathways,

CLEANING PROCEDURE

STANDARD DAILY CLEANING PROCEDURE

DAILY SELF CLEANING

1 Cleaning should be done at least once a day.(5 Mins Minimum)

If needed to change for different

Standard frequency should be 10.30 am and 12.30 am, and at
2 frequency, decide at CFT as per
end of each work day(as per factory work hours)
plant requirement.

Standard musical tune should be played to initiate self-

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cleaning

Standard cleaning schedule should be implemented for all

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areas of the plant.

CLEANING RESPONSIBILTY MAPS & SCHEDULES

Employee(s) working on machines should clean their machines

5 while all others should clean their workspaces/assigned areas
of the factory/office when the music is played

Heavy cleaning work, such as washing factory floor or doing a

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SEIRI should be considered as separate additional work

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 Checklist provided by maintenance.
A machine cleaning checklist should be provided for each
7 (Decide at CFT if need to develop
machine to be followed
differently)

Toilets/Bathrooms/Change Rooms may be cleaned by

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janitorial staff

Maintenance Dept. is responsible for repairs and adjustments

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found during cleaning

CLEANING TOOLS USAGE

Appropriate cleaning tools should be provided depending on

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the requirement/litter

Detergents/chemicals used in cleaning should be checked for

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safety of products manufactured and/or type of workplace

No excess cleaning tools allowed, all should be only as per

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requirement

CLEANING TOOLS STORAGE

Specified locations should be allocated, demarcated and used

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for storing cleaning tools/agents/chemicals/equipment

Cleaning tool hanging board should be implemented with

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outline of each tool if possible

MACHINERY/EQUIPMENT/TOOLS/FURNITURE

Daily cleaning procedure is imperative to maintain

machines/equipment/tools in original condition. Periodic Decide monitoring frequency and
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monitoring should be done of adherence to the schedules and methods at CFT
procedures.

GENERAL APPEARANCE OF CLEANLINESS

Garden area should be well kept. (Overgrown grass moved,

16 Covered by 5S audit
shrubs/bushes/trees trimmed, fallen leaves swept. etc.)

17 Office areas should be devoid of dust and well maintained. Covered by 5S audit

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 WASTE COLLECTION BIN/ CONTAINER MANAGEMENT POLICY

• Waste bin management is one of the many areas, which needs to run efficiently for 5S to
sustain. Proper maintenance and management of the waste bin not only enables to get rid
of unwanted items but also provides the company a clutter free environment.

• 3 main areas are identified where waste bins need to be implemented.

o Workplace – All departments within the plant.
o Garden Area
o Canteen

• 6 main known types of waste are managed through separate bins visually identified
through different colors. (NOTE 1:. You can think of a separate bin for any other type of
waste apart from the listed. Ex: Rubber bands, NOTE 2: Need to have sign labels/wording
as required by Scheduled waste license mainly in Washing/Printing units, NOTE 3: Need a
secondary storage for Hazardous waste, NOTE 4- other type of waste could be E-Waste as
we have separate project going on)

Waste Type Suggested Colors for Waste Container

Perishable (Food and Garden
Dark Green
Waste)
Paper / Cardboard Blue
Plastic/Polythene Orange
Fabric Offcuts Yellow
Glass Red
Metal Grey

Hazardous Waste

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• Waste bin arrangement can differ according to the area. This is shown as below:

o Workplace (Office Areas) - Paper, Cotton/Fabric & Plastic/Poly.

o Workplace (Operations) - Paper, Cotton/Fabric & Plastic/Poly.
o Workplace (Sewing) - Paper, Cotton/Fabric, Plastic/Poly & Thread Cone.
o Garden Area - Paper, Cotton/Fabric, Plastic/Poly & General Waste.
o Canteen - Paper, Cotton/Fabric, Plastic/Poly & Food Waste.

• Waste bins in any area needs to be placed next to each other accordingly starting from
Paper, Cotton/ Fabric, Plastic/ Polythene, Food Waste; General; Thread Cone. (Left-to-
Right)

• Sequence of waste bin placements should be decided as per practicality of the location /
dept they are placed in.
o ie. At Canteen Food Waste should be the 1st Bin, then Lunch Sheets then Paper.
Further Yogurt/ice cream cups and plastic wrappers should have a separate bin.
And Fabric offcuts used to dry hands could be provided at canteen exits or near
canteen taps where practical.
o ie. Office Areas should have Paper/ Cardboard waste bin as the 1st bin, then Fabric
offcuts and then polythene/plastic.
o ie. Production floors should Paper/ Cardboard waste bin as the 1st bin, then Fabric
offcuts then polythene/plastic and a separate bin for empty thread cone collection.

• Waste bins must be placed at a visible friendly location. Must not cause any interference
to movement or the natural flow of work. If possible, must be placed at a location for easy
removal of contents at scheduled removal times. Ideally, waste bins must be placed where
ever possible and place signs to encourage using them frequently.

• Parking lines should be of 4” corn yellow line on the sides and the back with the front
with a blue-white stripe marking, indicating that this object is not permanently placed
there but maybe moved for disposal of contents.

• Waste bin numbering is compulsory. Before starting to number make sure you have
identified all key locations for waste bin numbering. Identify how many waste bins and
the types of waste bins that are required for each area identified. Once all the mentioned
information is gathered, numbering can be started.

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 o Numbering should be placed on both the waste bin and on the location where the
respective waste bin is parked.

o Marked color of the number is the same as the waste bin color and for location and
white color for the waste bin.

o Numbering on the waste bin should be placed above the label & logo.
Day & time of removal will depend on the type of area. Example: Operation floors will need to be
continuously removed of waste whereas this is not the case with garden area.
o Day & time schedule is as follows:

Area Days Frequency Time

Workplace (Office) Daily 2 8.00am & 2.00pm
Workplace (Operations) Daily 4-5 8.00am, 10.30am, 1.00pm, 3.30pm & 5.00pm
Canteen Daily 3 8.00am, 2.00pm & 4.pm
Garden Daily 1 12.45pm

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1.14.1 West Segregation
1.13.1.1 West Bins- Name Boards

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20
21
22
 6” FROM THE

L/01
BIN

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 Note :- Waste bin code needs to be in corn yellow color.
The waste bin needs to be placed on top of the code. Code format is Arial* 130 bold.
(Painting, best to make pattern then paint on top of it.)
1.13.1.2. General Dust Bins

1.13.2. [Insert Plant Name] Waste Bin Index

Size Bin # Dept. Type Of Waste Location (Optional)

Large 1 STD Paper/ Cardboard -

Large 2 STD Plastic/ Polythene -

Small 1 CTD Plastic/ Polythene Fusing Section

Small 2 CTD Paper/ Cardboard Fusing Section

Large 3 CTD Paper/ Cardboard Gerber Room

Large 4 ADM Food Waste Lunch Room

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• Index Heading: Arial 18 Bold
• Index Table Heading: Arial 14 Bold

• Index Table Contents: Arial 12 Bold

• All Capitals and Centered

• Preferably Maintenance Department Needs to Have A Hardcopy Of The Index Displayed.

4”
• Department Code: Arial 72 Bold Number Code: Arial 48 Bold

• Placement of Sticker from Base: 3”

• Background of General Dust Bin Sticker Should Be the Department Color. Print It And Then
Laminate Using Cello Tape.

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PIPE LINE COLOR CODING

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 FUEL TANK LABELLING

6”

Pipe

Need white A4 sheets to print this. Need A4 laminating sheet.

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VALVE STANDARDIZATION

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 0.5” 0.5”

O O
Width : 0.5 inch
2.0” 2.0”
Length : 2 inches
C
Font : Arial 20 Bold
C

A B
Width : 1.7 inch

Length : 1.4 inches

C Font : Arial 11 Bold D

OPEN 1.4” OPEN 1.4”

1.7” 1.7”

• A & B is primarily used for Ball Valve A and C & D is primarily used for Ball Valve B and Gate Valves.
• For standard A & B, the correct way of reading open close direction is to observe the letter O in the
right way.
• If the letter O is in a 90 degrees angle, then it means close if the letter O is in the right way it means
its open.
• For standard, C & D it depends on the direction of opening only.

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 MACHINE IDENTIFICATION NUMBERING

1.18.1 Machine Identification Cording

Factory / Machine / No

XXXX/XXXXXX/0000

Ex-

HKKT/SEW/0001

HKMI/FUSING/0001

HKKT/SEW/0001
Method -
1. Font Arial Bold Size 16
2. 0.5 x 2.5-inch size Box.
3. Stick label at top left corner of the machine (if it’s any visibility or space issue stick it at
clearly visible area)
a. Make sure to stick label at same place in same type of machine.
b. Do not stick it on functional arias.
4. Need to manage maximum 16 digits for Code

1.18.2 Machine Index

Machine Machine C. Machine C. Serial Received

No Description Model Dept.
Code One Tow No: Date

• Keep machine index as soft copy.

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 RED TAG PROCEDURE

1.19.1 Definitions

• Red tags are used because of the implementation plan of Seiri (Sort), to tag items which have not
been used for a period of approximately 6 months OR which are not used frequently within a
department/institution but will be required for some other department or institution

• 5S is a method of creating a clean and orderly workplace that exposes waste and errors; it also
involves reviewing and rethinking each employee’s activity and making sure their work area
supports their work.

1.19.2 Scope

This document covers proper removal and identification of any physical asset from a
department/institution.

1.19.3 Procedure

1.19.3.1 Department responsibilities for storage of items in the Red Tag area
• An item should be Red tagged if it has not been used for a period of 6 months OR An
item should be Red tagged if it is and never will be utilized by departments.

• Any department staff member has the ability of red tagging an item after approval is
obtained from the relevant department head.

• Separate location should be allocated for overall factory for “Red tag area”

• Any asset placed in the red Tag Area should be placed in the location allocated for
departments.

• Any asset placed in the Red Tag Area must have a Red Tag (See Appendix A for Red
Tag template) affixed to it using a string tie; if not it will be disposed.

• A Red Tag must have the following information completed.

✓ Apply Date
✓ Department name
✓ Item Description
✓ Quantity
✓ Removal Date
✓ Authorized signature of item owner

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 ✓ Authorized signature of department head

• All assets in the Red Tag area should be included in the index placed at the entrance
of the Red Tag area.

• Each department’s Red tagged items are to be kept under lock & key, with a
duplicate key provided to the Maintenance manager.

• If a Red Tagged item is to be re-used, the following information needs to be filled into
the Red Tag and handed over to the Red/Yellow tag team before removal from the Red
Tag area.
✓ Date of removal from Red Tag area
✓ Authorized signature of Department Head
✓ Authorized signature of Maintenance Manager

• All assets in the Red Tag area will be disposed after the Removal date.

1.19.3.2 Red tag disposal team responsibilities

• The Red Tag area will be reviewed every 3 months by all the following:
o Manager of Maintenance Services
o Relevant Department Head

• If item removal date has passed.

• Weekly any new asset(s) added to the Red Tag area will be reviewed by all the
following:
o Maintenance staff
o Manager of Maintenance Services
o GM/Director (If the asset is deemed worth more than Rs.5000)

• The Red Tag Disposal Team will decide the actions for assets passed the removal date,
(Signature is required by Maintenance Manager and Director/GM once removal
method is decided)

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 1.19.4 Red Tag Template (A6)

* To be printed on Red A4 Sheet (4 per sheet).

Date item is
placed into Area item
red tag area came from

Brief
description

Quantity if
more than 1
Tick all relevant
item statuses
Date item is
to be
removed Signature of
from red tag
department
area head

Date item was Signature from

removed from head of
red tag area department to
which item is
If item is to be released
re-used by a Tick relevant
department, method of item
<tick here> release from red
tag area if item is
not re-used before
removal date

Signature of GM/Director
Signature of
Maintenance Manager

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 RED TAG AREA NAME BOARD

One Common place for entire factory (All departments) which is under maintenance manager.

Specifications of the Board

Size 18”*6”

Font =Areal , Font color White

Back ground Color = Red

Boarder Color = White

Before/ After Comparison Display

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 OIL & FLUID STANDARDS (OIL & LUBRICANT USED FOR ALL MACHINERY IN THE PLANT)

All oil and fluid will be separated based on two categories as “Flammable” “Non-flammable”
Two separate labels are introduced with international pictograms as shown below

The oil/fluid code will be taken from the chart given below

Type of Fluid/Liquid Flammability Purpose Codes

Thinner Highly Flammable Painting purposes HF-1
Surgical Spirit Highly Flammable Machine cleaning HF-2
Diesel Highly Flammable Use for boilers HF-3
Petrol Highly Flammable Grass cutter machine HF-4
Furnace oil Highly Flammable Boiler HF-5
Paint remover Highly Flammable Paint removing HF-6
High Speed High Flammable Machine cleaning HF-7
Kerosene oil High Flammable used as a laxative HF-8
PVC solution High Flammable Plumbing HF-9
Grease High Flammable Machine maintenance HF-10
Liquid Petroleum Gas (LPG) High Flammable Used in the kitchen HF-11
Coconut oil High Flammable Used in the kitchen HF-12
Lupromax High Flammable Boiler HF-13
Paint High Flammable Boiler HF-14
Pull out Non Flammable Stain removing NF-1
Smooth Fuse Non Flammable Fusing machine cleaning NF-2
Easy On Non Flammable Ironing purpose NF-3
Compressor Oil Non Flammable Compressor NF-4
Machine Oil Non Flammable Machine maintenance NF-5
WD40 Non Flammable To stops squeaks of machines NF-6
Contact cleaner Non Flammable Circuit cleaning NF-7
Silicon oil Non Flammable Stop thread breakdowns NF-8
Soldering fluid Non Flammable Welding purposes NF-9
Ink Erad Non Flammable Spot cleaning NF-10
Eco clean Non Flammable Cleaning purposes NF-11

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 Super dry Non Flammable Cleaning purposes NF-12
Soda Ash Non Flammable Drinking water cleaning NF-13
Chlorine (Cl) Non Flammable Drinking water cleaning NF-14
Boiler chemical - 150 Non Flammable For boilers NF-15
Boiler chemical - 103 Non Flammable For boilers NF-16
Boiler chemical - 140 Non Flammable For boilers NF-17
Paint Non Flammable Painting NF-18
Hydrex 2234 Non Flammable Cooling tower NF-19
Hydrex 70111 Non Flammable Cooling tower NF-20
Hydrex 7908 Non Flammable Cooling tower NF-21
Hydrex 1260 Non Flammable Boiler NF-22
Hydrex 1320 Non Flammable Boiler NF-23
Hydrex 1566 Non Flammable Boiler NF-24
LCD Cleaner Non Flammable LCD Display clean NF-25
Foam cleaner Non Flammable Computer body clean NF-26
Color
Flammable Label
Base = Red & Black
Pictogram = Red & White

Non-flammable Label
Base = Green & White
Pictogram = Green & White
Size
Length of a label = 5cm (1.96”)
Width of a label = 3cm (1.18”)

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 TROLLEY LABELLING

•
•
<XXX> - Department Code
<01> - Trolley number
XXX 3.8”

inside department

01
3.8”
Characteristics of the Label

• Base Color: Golden yellow

• Font Color: Black
• Font Type: Arial
• Font Customizations: Bold
• Font Size: 105
• Dimensions = 3.8” x 3.8”

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Preparation of label

Six Stickers to be printed on one white A4 sticker sheet as shown below:

A4 sheet margins

• Side margins = 0.35”

• Top margin = 0.2”
(Optional: label can be pasted onto transparent Plastic Square after laminating or you can directly
print on a laminated sticker)

Label Placement

Label to be reverted directly on the front and back center on the lowest/Middle part (Depend) of
the trolley. Label need to be seen properly.

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 CLEANING TOOL HANGER & OTHER EQUIPMENT PLACEMENT

Method 01 (With Shadow Board)

1) There should be specified locations/ places to keep the cleaning tools

2) Cleaning Tools and Equipment should be hanged on a shadow board

Method 02 (Without Shadow Board)

1) There should be specified locations/ places to keep the cleaning tools

2) Cleaning Tools and Equipment should be hanged on a board with a numbering and
without drawing the outline

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Cleaning Agents Placement

Method 01 (Below cleaning tool hanging board)

1) Cleaning agents should be kept above the cleaning tools hanging board

Method 02 (Above cleaning tool hanging board)

1) Cleaning agents should be kept below the cleaning tools hanging board

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 CLEANING TOOL HANGER

Tool list

1. Screwdriver 4

2.

3.Level 1

4.

5. Pliers 3

Tool Board

Color White

Size (Medium) 4’7’’ x 2’5’’

Size (Large) 5’7’’ x 3’2’’

Tool List

Placement of tool list - left side to the tool board

Font for numbering - Arial

Font size - 32

Color of outline - Black (2mm)

2m
m

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Tool Numbering

•
•
Font
Font Size
Arial
36 12

1 2 3 4

Numbering direction

11 12

TOOL ID

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 DEPARTMENTS/ SECTION / ROOM NUMBERING

• Number follows the same format of the board as above.

• The number follows the building number and section number
• Same number goes to the key tag and Site map

KEY HANGER BOARD

KEY TAG

It is compulsory to have a key tag in every key in the factory.

Content of the key tag

Department number and door number need to be indicated in the center of the key tag. First two
digits of the key tag will be represented the department number and second two digits will be the
door number two numbers will be separated by a dash sign. Both departments and door numbers
need to be indicated in two digits always as showing in below picture.

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 Room Number

Department Number

Measurement of the key tag

Size = Length 2.5inches Width= 1inch

Font = Calibri

Font size= 60

Additional information

Use the given excel format when you are preparing the key tags. Just feed sensory details and take
the printouts using relevant color A4. Then laminate it. Use some non-metal tread for connect the
key. Excel sheet will be provided an as below, should enter the department number and the room
number in “Enter numbers” sheet. And should get the printout of the other sheet.

Set 01 Set 02 Set 03 Set 04 Set 05 Set 06 Set 07 Set 08

Department Cutting Production HR Production Cutting HR Cutting HR
Department no 1 2 34 5 67 8
Room no 11 12 13 14 15 16 17 18

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45
 DEPARTMENT COLOR CODES

Department Color Sample Remarks

Color

HR IT230 Parrot green

Training Center (HR)

Medical Center (HR)

Stores /LAB IT 170 pink

Cutting IT 220 Turquoise

Production IT 150

Finishing IT 371 Cyber HP Orange

Quality Assurance IT 210 Lemon

Workstudy IT 120 Ocean

Planning IT 130 Lagoon

Fabric/Trim inspection White

IT IT 200 Gold

Maintenance IT 100 Ivory

OS Pink

Sample Purple

Merchandizing IT 321 Cyber HP Green

Export IT 115 CANARY

Finance. / Technical IT 185 lavender

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 PANEL BOARD TRACTABILITY/ NUMBERING/ DEMARCATION

1.29.1 Panel Board Tractability

1.29.2 Panel Board Numbering

Code references –
Transformer / MSB / MDC / DB
Rule and conditions
1. Every base should be number base on above cording system
a. Stick 1 x 2-inch size sticker
b. Font Size
i. Transformer cored 36 Arial Bold
ii. Sub panel cored 24 Arial Bold
c. Back Ground Color Yellow and black color out line

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 DB
T/2/2/2
2. Stick Sticker at left top corner of the base
3. Draw panel map path from the transformer and stick at the below to the panel base
number
4. Generator path also should address on the plan
5. DB of Fire also clearly display and highlighted in red color

6.
7.
8.
T/2/2/2
DB

Sub Panel

1.29.3 Panel Board Demarcation

Panel board should highlighted through Red and White color Tape as above ( 1cm turn for side and rest
top of the cover

Identification of breakers

1. Each and very breaker should identify

01 02
2. Stick below standard identification sticker aligning to each.

3. Need to have map with location as below related to every breaker number

4. Need to name and clearly name the Bus bar as ‘A”, ‘B” …. at the panel and the map

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 LIGHT SWITCH NUMBERING

• In the above given example 3 switch panels are placed close to each other for which a common
map has been drawn.

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 • The map shows the identification for the lights and fans represented by these 3 switch panels.

• Rooms A & B have their own switch panels for lights and fans, hence a separate map will be
drawn if need be.

• In an instance where multiple switch panels are placed in one location, a common map will be
drawn to represent all the lights and fans represented by each switch.

1.30.1 Directions

Important Notes:

Make sure that the letters/numbers are centered in accordance with the shape

Please note that the Light sign in the production floor is larger than the Light sign to be used in the office
area.

1.30.2 Factory Floor Light Panels

• The light signs should be printed in Yellow A4 paper.

• The Light Signs need to be laminated for strength and durability.

• The Sign needs to be hung on the Lights. Must be mainly visible to the user of the switch
panel. Preferably on the Front or Sides of the light frame by the method of hanging.

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 • The Sign will be Hung in a position that would be visible for the user of the switch panel.

• Need to keep Uniformity & Visibility as much as possible – Eg – in a specific Department

you can’t hang one item on the left, then the next in the middle and other on the right,
unless the view is obstructed. Need to ensure that uniformity and Visibility is the Highest.

1.30.3 Production Floor Lighting

Hanging sign for lights – 12cm width, 14cm height

Font – Arial size 155 (Bold)
Color – Yellow, Position - Centered

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Switch Panel sticker – 1.2cm width, 1.2cm height
Font – Arial size 14
Color – Yellow (Lights) Blue (Fans)

Position: Centered

1.30.4 Office Areas/Board Rooms/ Flat Light Panel Areas

The Lights that can be hang from the frame should be done so – this method is mainly for the Box
light Specs Hanging sign for lights – 9.6cm width, 10.77cm height, Font – Arial size 120 (Bold),

Position – Centered
• The sign would be Round in shape as follows

52
 FAN NUMBERING

• The fan sign should be printed in Light Blue color A4 paper.

• The sticker will be hung and tied on the “down rod”
• The stickers should be placed facing the direction of the switch panel.

• Fan sticker (laminated) – 6cm diameter

• Font – Arial Black size 130
• Color – Blue
• Position: Centered

53
 A/C AMBIENT TEMPERATURE DISPLAY

DISPLAY BOARDS

1.33.1 SQDC Tower

54
1.33.2 Production Display Board

HOURLY PRODUCTION MONITORING BOARD - PRODUCTION DEPARTMENT REVIEW

BY
UPDATE
BY
DATE
DD / MM / YYYY

TEAM PLAN 1st HOUR 2nd HOUR 3rd HOUR 4th HOUR 5th HOUR 6th HOUR 7th HOUR 8th HOUR 9th HOUR
NO PCS LINE OUT DEFECT % P2P LINE OUT DEFECT % P2P LINE OUT DEFECT % P2P LINE OUT DEFECT % P2P LINE OUT DEFECT % P2P LINE OUT DEFECT % P2P LINE OUT DEFECT % P2P DEFECT % Defects% P2P LINE OUT DEFECT % P2P

TOTAL

48”

Font- EXO

Note: - Standardized art work will be send with manual.

1.33.3 5S Road Map Board

Font- EXO

Note: - Standardized art work will be send with manual.

55
1.33.4 Obey Room

Name of the Visual Department

Factory Vision & Mission Obeya Room
Theme of the year Obeya Room
Hoshin Obeya Room
Project A3s Obeya Room
Plant KPI Display SQDC Obeya Room

Note: - Standardized art works will be send with manual.

1.33.5 PDCA Room

56
Name of the Visual Department
PDCA Chart Obeya Room
Fishbone Obeya Room

5Whys Display Obeya Room

Note: - Standardized art works will be send with manual.

1.33.6 KPI Display Board

Note: - Standardized art works will be send with manual.

57
 FILE LABELING 2.5” or 1.5”

(1) Department Code

OSD

SAMPLE FILE FORMAT

(2) File Topic

Box File

RC/05

99
VOL
A
FROM
TO
12 :1
: 23/07/2014
: 23/07/2014
(3) File No:

HK - MI (4) Factory Code & Logo

4.5cm

(From Bottom of the File)

58
Topic Descriptions
Department Code – See below Appendix 01

File Topic = The Name of the file

File No – File Number start from 01 at beginning of each equipment from left to right.

FURNITURE LABELLING

Equipment Short Code

Cupboard CU
Rack RA
Table TA
Wall WA

Equipment code should be pasted on left side top of the equipment (Shown in figure 02)

FONT: ARIAL

SIZE 16 BOLD
RA/01 0.5”

2’’

59
 TABLE DEMARCATION METHODOLOGY

Note: - Dimension should be 1 inch

60