20 elementos marcados para la gestión de 5S en Valve Workshop
Mar 31, 2022
Normas Generales (comunes en los talleres)
Disciplina de comportamiento
1. Dentro y fuera de la Sala de Talleres
Estándar: Al entrar y salir deltaller de válvulaspasillo, debes cerrar la puerta detrás de ti. Al abrir o cerrar la puerta, debe empujarla suavemente. No lo golpee con violencia para evitar dañar la puerta de vidrio.
2. Caminando en el Pasaje del Taller
Estándar: camine en el medio del pasillo en el lado derecho del pasillo cuando vaya a trabajar en el taller. No se permiten juegos ni carreras rápidas. Más de dos personas pueden formar una formación y caminar conscientemente en formación.
3. Zapatero privado
Estándar: después de cambiarse los zapatos, el zapatero privado debe cerrarse con llave y la puerta del zapatero debe abrirse a voluntad. Si la llave del zapatero se cae, se debe registrar con el oficial de seguridad y se debe obtener la llave de repuesto que coincida con la cerradura. La cerradura del zapatero no debe romperse a voluntad, de lo contrario, la compensación debe hacerse de acuerdo con el precio original.
4. Uso del Dispensador de Agua
Estándar: cuando reciba agua caliente, tenga cuidado de no quemarse con el agua caliente. Hay agua caliente en el grifo marcado en rojo a la izquierda. Después de recibir el agua, cierre suavemente la puerta del gabinete para beber. Además, si hay té en la taza de agua, no lo vierta en la piscina, vierta en el balde al lado.
5. Limpieza del suelo en la despensa y el área de cambio de zapatos
Estándar: los bocadillos, la caspa de frutas, etc. que se comen en la despensa no deben tirarse al suelo, sino que deben tirarse a la basura.
6. Gestión de libros y publicaciones periódicas en la despensa
Estándar: Después de tomar prestados los libros en el estante de libros y periódicos, deben colocarse cuidadosamente en el estante de libros y periódicos y no sacarlos de la despensa.
7. Ropa personal
Estándar: Debe usar ropa de trabajo para trabajar. No use pantalones cortos y pantalones cortos para ingresar al taller, y no use joyas, como anillos, collares, aretes, etc. Los niños no deben usar el cabello largo y las niñas deben atarse el cabello con fuerza en sus sombreros. Al ingresar al taller, debe usar ropa electrostática y la cremallera debe estar tirada hasta el final.
8. Postura sentada en el trabajo
Estándar: mantenga las rodillas juntas de forma natural. Mantenga las piernas erguidas o de lado. No cruces las piernas. Al menos dos tercios de la silla están ocupados. La distancia entre las personas debe ser de al menos 20 CM, y el taburete debe estar a unos 5 cm de la línea amarilla.
9. Marca
Estándar: la marca emitida por la empresa debe completar los contenidos anteriores de acuerdo con los requisitos, y la escritura a mano debe ser clara. En la columna del departamento, "taller en el extranjero" debe escribirse de manera uniforme. No está permitido garabatear en él y se debe adjuntar una foto de una pulgada del individuo. Cuando trabaje, debe colgar la marca en el lado derecho de su instrucción de trabajo correspondiente y retirarla después del trabajo.
10. Colocación de heces
Estándar: al trabajar, la superficie formada por los dos pies en el exterior del taburete debe ser paralela a la línea amarilla, y la distancia entre los pies y el taburete debe mantenerse en aproximadamente 1 CM. La línea amarilla no debe presionarse. Después del trabajo, empuje el taburete en la línea de montaje y tírelo hacia adentro. El taburete debe estar cerca de la tráquea por debajo.
11. Limpieza de toallas
Estándar: las toallas deben limpiarse a fondo con detergente en polvo o detergente después de 5 segundos todos los días, y no debe haber manchas evidentes en las toallas limpias.
12. Gestión de objetos personales
Estándar: Los artículos personales, como agua potable, refrigerios, productos para el cuidado de la piel no deben ingresar al taller. No juegues con los teléfonos móviles en el trabajo.
13. Gestión de la Distribución de Materiales Auxiliares de la Empresa
Estándar: Los accesorios proporcionados por la empresa, como brazaletes electrostáticos, guantes electrostáticos y zapatos electrostáticos, deben guardarse adecuadamente por sí mismos. No haga garabatos ni los dañe a voluntad.
14. Proceso de operación
Estándar: No hables, rías y discutas cosas no relacionadas con el contenido del trabajo durante el trabajo.
Gestión de identificación
1. Identificación de materiales
Estándar: el logotipo mide 7,5 cm de largo y 1,5 cm de ancho, y se coloca uniformemente en la ranura para tarjetas en la parte frontal de la caja de material.
2. Marcado en la Línea de Montaje
Estándar: el ancho del logotipo es de 1 cm y la longitud depende del contenido real del logotipo. Está atascado en el medio de la línea de posicionamiento.
3. Ground Signs
Standard: The width of the logo is 4.5cm. The length depends on the actual content of the logo, and it is stuck in the middle of the positioning line.
4. Status Identification Card
Standard: The logo is 9.5cm long and 8.5cm wide. It is clamped on the turnover box to mark the state of the inner plate of the turnover box.
5. Entrance and Exit Signs
Standard: The diameter of the sign is 10cm, and the "Push" plate is affixed at 5cm above the door lock. The "Pull" plate is affixed at the back of the door, at the same height.
6. Safety Identification of Electric Cabinet
Standard: The logo is 6cm long and 8cm high.
7. Fire Extinguisher Indication Mark
Standard: The logo is 30cm long and 15cm high.
8. The Stop, Running Logo of Smoke Purifier Equipment
Standard: the logo is 1.5cm long and 1cm wide.
9. Flower Pot Positioning and Identification
Standard: The flower tray is uniformly positioned in a circular area with 1cm long and 1cm wide green adhesive, and labeled with a logo.
The Billboard and Card
1. Work Station Card
Standard: Dimensions are 20cm long and 15cm wide.
2. Line Body Tag
Standard: Dimensions are 58cm long and 35cm wide.
3. Billboard
Standard: Billboard in the workshop passage, with a uniform height of 150cm, the length of which depends on the actual content, is uniformly mounted with PVC board, black frame, uniform Logo and shading background.
4. Test Equipment Status Identification Plate
Standard: Dimensions are 20cm long and 15cm wide.
Color Management Method
1. Yellow
Standard: The yellow area is used to place goods to be repaired, turnover vehicles, turnover boxes, etc. It can also be used as the identification of the main passage of the workshop.
2. Red
Standard: Red areas are used to locate defective products, garbage cans, fire extinguishers, fire hydrants, dangerous areas, etc.
The AI Workshop 5S Implementation Standards
1. The Ground
Standard: No materials, garbage, scraps of paper should be dropped on the ground, and the ground should be kept clean during working hours. Clean the corner areas of the workshop regularly (at least once every three days), such as fire extinguishers and under the shelves.
2. Equipment Maintenance
Standard: The equipment should be maintained after work every day, and the surface of the equipment should be kept clean with a towel so that no obvious dust can be felt by hand. The air conditioning and shelves of the workshop should be maintained at least once every three days.
3. Material Placement
Standard: Materials should be uniformly and neatly placed on the shelf, different materials should be placed separately, and they should not be mixed, with accurate material identification. When the shelf is not in use, corresponding dustproof measures should be taken.
4. Maintenance Area
Standard: During maintenance work, the top plate of the desktop should not be placed in disorder but should be placed neatly on the L-frame, and the maintenance records should be updated in time. When the maintenance platform is not in use, the power supply of the lighting lamp should be turned off, and the garbage dropped from the ground in the maintenance area should be cleaned up in time.
5. Operation Area
Standard: Earplugs should be worn during operation, and the operation should be carried out according to the requirements of the operation instruction. The desktop should be placed neatly, and the garbage left by the unpacked box and the board to be AI should be placed separately, not together. The electrostatic skin of the desktop is grounded.
6. Checklist
Standard: Routine checklist should be checked before starting up every morning. Check the temperature and humidity meter at 9: 00 a.m. and 3: 00 p.m. every day, and make a temperature and humidity curve.
7. Placing Turnover Cars in Semi-finished Products Area
Standard: When not in use, the turnover truck should be placed in the designated area, keeping the principle of being parallel or symmetrical with the designated area, and it should not be skewed, beyond the planned area or pressed against the line.
8. Placement of Empty Turnover Boxes
Standard: Turnover boxes (including empty boxes and in-use ones) should be placed in the planning area, aligned by the outer yellow line, with a height limit of 2 floors.
9. Garbage Bin Area
Standard: Garbage bins should be cleaned regularly. The garbage should not fall on the ground. The garbage in the bins should not exceed the horizontal line of the garbage bins, and the garbage should be cleaned in time when it is full. Towels should be thoroughly cleaned once a day after 5S cleaning.
10. PCB Temporary Release Area
Standard: The board height in the temporary storage area is limited to 2 floors. The unpacked board cannot be directly placed on the carton but should be put back into the turnover box again, and then taken out when it is used.
11. Riveting Machine Area
Standard: The materials in the material box on the desktop should be clearly marked, and the physical objects should be consistent with the marks. Pay attention to 5S on the desktop when it is not working, and irrelevant items should not appear on the desktop.
12. Loading Area
Standard: Because there are many pins in the feeding area, it needs to be especially helpful for cleaning the ground, which should be cleaned every hour.
SMT Workshop 5S Implementation Standards
1. The Ground
Standard: No materials, garbage, scraps of paper should be dropped on the ground, and there should be no stains on the ground. The ground should be kept clean during working hours. Clean the corner areas of the workshop regularly (at least once every three days), such as fire extinguishers and under the shelves.
2. Equipment Maintenance
Standard: The equipment should be maintained after work every day, and the surface of the equipment should be kept clean with a towel so that no obvious dust can be felt by hand. The air conditioning and shelves of the workshop should be maintained at least once every three days.
3. SMT Material Preparation Rack
Standard: The material preparation rack should be placed in the planned area after the materials are prepared, and documents such as BOM and other items cannot be placed on Feida.
4. Temporary Discharge Area of SMT Tray
Standard: The number of trays in each compartment on the cabinet is limited to 10 trays. The trays in each compartment should be placed neatly and marked with materials. The use of trays should follow the principle of first in, first out.
5. Semi-finished Product Placement Area
Standard: Semi-finished products in the material preparation area should be uniformly placed on the vehicle, and placed neatly by the outer yellow line. Semi-finished products in the non-material preparation area are placed on the ground, uniformly aligned against the wall, and about 10cm apart between different models.
6. Red Glue/Silk Screen Brushing Area
Standard: During the operation, the boards should be placed on the L-frame piece by piece, not directly on the desktop. Due to its nature, special attention should be paid to the cleanliness of the desktop in this area.
7. Connecting Station
Standard: The boards on the L-rack should be placed according to the standard in the figure, and the reports on the table should be updated in time.
8. Post of Visual Inspection
Standard: Except for L-frame, transparent glue, distribution card and distribution card, no other items can be placed on the desktop in the visual inspection area. The above items should be placed according to the specified positioning.
9. Steel Mesh Placement Area
Standard: Steel nets should be placed in one-to-one correspondence according to the numbers on the form. Steel nets in each grid should be placed neatly and cleaned up after use.
10. Freezer
Standard: The use of red glue and solder paste in the freezer should follow the principle of first-in, first-out, and the red glue should be placed in the steel ring in order. When it is taken out for use, it is necessary to register and check the number to ensure that the data on the card is consistent with the actual data. At the same time, the temperature and humidity should be well controlled, and regular spot check records should be made.
11. Thawing Area
Standard: The unfrozen red gum and solder paste should be placed in the designated area, not at will, and the spot check record should be made.
12. Pick-up Belt with Dustbin
Standard: The material belt in the dustbin should be cleaned every two hours, and the material belt should not exceed the dustbin. If any material belt exceeds the dustbin, it should be sorted out in time to avoid leaking out of the dustbin.
13. Sitting Posture
Standard: When operators operate, stools should be uniformly close to the yellow line and parallel to the yellow line. When leaving the operation area, it is necessary to return the stool to its place and approach the connecting platform uniformly.
Standards for 5S Implementation in MI Workshop
1. Production Information Billboard
Standard: The daily production situation on the board should be updated in time, the production capacity of each hour should be updated within half an hour, and the skill matrix should be updated once a month.
2. Filing Cabinet
Standard: Materials and PCB boards are not allowed to be placed in the filing cabinet. SOP, reports, accessories, notebooks, calculators can be placed. All placed items should be clearly positioned and marked and placed according to the marked contents.
3. Placing the Turnover Car in the Fixture Section
Standard: Only one turnover car can be placed in this area. When there is only the last box of the board in this car, the material clerk can come from SMT to get the board. After changing the turnover car, the turnover car with the empty box should be pulled to the AI workshop immediately. The turnover car should be placed according to the positioning, and the line should not be pressed.
4. Hanging of SOP, Grape Cards and Brand Names
Standard: Grape cards are hung on the left side of the corresponding area of each station. The factory brand is hung in the middle, and SOP is hung on the right side. It is hung strictly according to the positioning points.
5. Electrostatic Bracelet Wear
Standard: The electrostatic bracelet is worn too loosely, and the metal surface is not completely in contact with the skin, so the electrostatic grounding effect cannot be achieved. The electrostatic bracelet should be properly worn at the fixed station, and the spot check should be carried out in time (to ensure that it is in good condition and grounded). The mobile personnel on-site should wear electrostatic gloves.
6. Turnover Box Handling
Standard: Dragging the turnover box will cause the materials in the turnover box to collide, and at the same time, it is easy to abrade and damage the floor. The turnover box should be lifted and transported or checked by the turnover car to avoid the vibration and wear caused by the direct friction between the turnover box and the ground.
7. Placement of Tools
Standard: Use foam to carve out models of tools needed for daily production, such as brushes, scissors and fix them in a fool-proof manner. Put the tools to slide, and place them according to the tracks.
8. Material Identification
Standard: For the materials whose thread body is in use, each material has at least one material identification, which needs to be printed by computer and cannot be changed manually.
9. Working Instruction
Standard: Each job post needs to be provided with an operation instruction, and no job can be done at the station without an operation instruction, except for new employees who have just come in to study.
10. Form Update
Standard: The routine checklist of the wire body that needs to be updated every day should be completed before 9: 00 a.m. on the same day, such as the routine checklist of the electrostatic bracelet, maintenance list of the assembly line, maintenance list of soldering iron, ICT maintenance list, FCT maintenance list. The grape card should be updated before the end of the day, and can't be delayed until the next day.
11. PCB Placement
Standard: PCB boards that are too late for operation should be picked up and neatly placed on the L-frame, and illegal operations such as overlapping, pushing, throwing and dropping are not allowed, which may easily lead to bad phenomena such as pad cracks, patches and components falling off, which will bring hidden dangers to the quality.
12. Chemical Control
Standard: Use the designated container to place chemicals, and make a good mark. It is easy for others to drink and misuse chemicals such as plate washing water and moistureproof oil in beverage bottles, endangering personal safety.
13. Wrapping the Power Cord
Standard: The power cables of all kinds of power instruments and equipment are placed in disorder, which is easy to contact with the human body, and there is a potential safety hazard. They should be folded and neatly tied with cable ties to fix the power cables.
14. Soldering Iron, Batch Management
The temperature and batch parameters of soldering iron can't be adjusted privately but should be adjusted by professional spot check personnel to avoid poor operation quality caused by too high or too low parameters. If any abnormality is found, the equipment management personnel should be informed for adjustment or maintenance.
15. Material Management
Standard: Good materials should be separated by different black boxes, and cannot be mixed. The height limit of the digital tube is 10 floors, and that of the relay is 6 floors. The defective products should be put in red material boxes, which can be put together. The defective products (including defective boards) should be cleaned up before the end of the day.
16. Assembly Line Maintenance
Standard: The assembly line needs to be maintained after work every day, with the help of towels and rags. Towels are mainly used to clean the dust on the surface of the equipment, and cannot be used to clean the oil in the equipment. A rag is used to clean the stains in the equipment that are difficult to clean, such as oil stains. Towels should be cleaned after use and hung in the designated area.
17. Place Items on Site.
Standard: On-site articles should be placed in accordance with the principle of "three-set", that is, there should be clear positioning (L-frame, soldering iron, turnover box, etc. should be placed in the positioned area, but not beyond the area or pressing the line), and there should be signs. The number of articles placed should not exceed the standard (the upper limit of the L-frame is 8 pieces), and large materials should not be placed on stools.
18. Use of Towels and Rags
Standard: Towels can only clean the dust on the surface of the equipment, but can't clean the dirt that is difficult to clean, such as oil stains. You can use a rag to clean the oil stains.
19. Placing Large Materials
Standard: The height of large digital tubes is limited to 10 floors, and that of transformers and relays is limited to 6 floors. Garbage in garbage bins should be recycled in time.
20. Temporary Storage Area and Mantissa of Finished Products at the Back of MI
Standard: The temporary storage area at the rear section of the MI line body is divided into 8 grids. If any finished products are temporarily not put in storage due to abnormality, they should be placed in the positioning area, and the line should not be pressed or placed on the channel, with a height limit of 6 floors, which should be placed neatly. The boards in the mantissa area should be cleaned up on the same day.
Disciplina de comportamiento
1. Dentro y fuera de la Sala de Talleres
Estándar: Al entrar y salir deltaller de válvulaspasillo, debes cerrar la puerta detrás de ti. Al abrir o cerrar la puerta, debe empujarla suavemente. No lo golpee con violencia para evitar dañar la puerta de vidrio.
2. Caminando en el Pasaje del Taller
Estándar: camine en el medio del pasillo en el lado derecho del pasillo cuando vaya a trabajar en el taller. No se permiten juegos ni carreras rápidas. Más de dos personas pueden formar una formación y caminar conscientemente en formación.
3. Zapatero privado
Estándar: después de cambiarse los zapatos, el zapatero privado debe cerrarse con llave y la puerta del zapatero debe abrirse a voluntad. Si la llave del zapatero se cae, se debe registrar con el oficial de seguridad y se debe obtener la llave de repuesto que coincida con la cerradura. La cerradura del zapatero no debe romperse a voluntad, de lo contrario, la compensación debe hacerse de acuerdo con el precio original.
4. Uso del Dispensador de Agua
Estándar: cuando reciba agua caliente, tenga cuidado de no quemarse con el agua caliente. Hay agua caliente en el grifo marcado en rojo a la izquierda. Después de recibir el agua, cierre suavemente la puerta del gabinete para beber. Además, si hay té en la taza de agua, no lo vierta en la piscina, vierta en el balde al lado.
5. Limpieza del suelo en la despensa y el área de cambio de zapatos
Estándar: los bocadillos, la caspa de frutas, etc. que se comen en la despensa no deben tirarse al suelo, sino que deben tirarse a la basura.
6. Gestión de libros y publicaciones periódicas en la despensa
Estándar: Después de tomar prestados los libros en el estante de libros y periódicos, deben colocarse cuidadosamente en el estante de libros y periódicos y no sacarlos de la despensa.
7. Ropa personal
Estándar: Debe usar ropa de trabajo para trabajar. No use pantalones cortos y pantalones cortos para ingresar al taller, y no use joyas, como anillos, collares, aretes, etc. Los niños no deben usar el cabello largo y las niñas deben atarse el cabello con fuerza en sus sombreros. Al ingresar al taller, debe usar ropa electrostática y la cremallera debe estar tirada hasta el final.
8. Postura sentada en el trabajo
Estándar: mantenga las rodillas juntas de forma natural. Mantenga las piernas erguidas o de lado. No cruces las piernas. Al menos dos tercios de la silla están ocupados. La distancia entre las personas debe ser de al menos 20 CM, y el taburete debe estar a unos 5 cm de la línea amarilla.
9. Marca
Estándar: la marca emitida por la empresa debe completar los contenidos anteriores de acuerdo con los requisitos, y la escritura a mano debe ser clara. En la columna del departamento, "taller en el extranjero" debe escribirse de manera uniforme. No está permitido garabatear en él y se debe adjuntar una foto de una pulgada del individuo. Cuando trabaje, debe colgar la marca en el lado derecho de su instrucción de trabajo correspondiente y retirarla después del trabajo.
10. Colocación de heces
Estándar: al trabajar, la superficie formada por los dos pies en el exterior del taburete debe ser paralela a la línea amarilla, y la distancia entre los pies y el taburete debe mantenerse en aproximadamente 1 CM. La línea amarilla no debe presionarse. Después del trabajo, empuje el taburete en la línea de montaje y tírelo hacia adentro. El taburete debe estar cerca de la tráquea por debajo.
11. Limpieza de toallas
Estándar: las toallas deben limpiarse a fondo con detergente en polvo o detergente después de 5 segundos todos los días, y no debe haber manchas evidentes en las toallas limpias.
12. Gestión de objetos personales
Estándar: Los artículos personales, como agua potable, refrigerios, productos para el cuidado de la piel no deben ingresar al taller. No juegues con los teléfonos móviles en el trabajo.
13. Gestión de la Distribución de Materiales Auxiliares de la Empresa
Estándar: Los accesorios proporcionados por la empresa, como brazaletes electrostáticos, guantes electrostáticos y zapatos electrostáticos, deben guardarse adecuadamente por sí mismos. No haga garabatos ni los dañe a voluntad.
14. Proceso de operación
Estándar: No hables, rías y discutas cosas no relacionadas con el contenido del trabajo durante el trabajo.
Gestión de identificación
1. Identificación de materiales
Estándar: el logotipo mide 7,5 cm de largo y 1,5 cm de ancho, y se coloca uniformemente en la ranura para tarjetas en la parte frontal de la caja de material.
2. Marcado en la Línea de Montaje
Estándar: el ancho del logotipo es de 1 cm y la longitud depende del contenido real del logotipo. Está atascado en el medio de la línea de posicionamiento.
3. Ground Signs
Standard: The width of the logo is 4.5cm. The length depends on the actual content of the logo, and it is stuck in the middle of the positioning line.
4. Status Identification Card
Standard: The logo is 9.5cm long and 8.5cm wide. It is clamped on the turnover box to mark the state of the inner plate of the turnover box.
5. Entrance and Exit Signs
Standard: The diameter of the sign is 10cm, and the "Push" plate is affixed at 5cm above the door lock. The "Pull" plate is affixed at the back of the door, at the same height.
6. Safety Identification of Electric Cabinet
Standard: The logo is 6cm long and 8cm high.
7. Fire Extinguisher Indication Mark
Standard: The logo is 30cm long and 15cm high.
8. The Stop, Running Logo of Smoke Purifier Equipment
Standard: the logo is 1.5cm long and 1cm wide.
9. Flower Pot Positioning and Identification
Standard: The flower tray is uniformly positioned in a circular area with 1cm long and 1cm wide green adhesive, and labeled with a logo.
The Billboard and Card
1. Work Station Card
Standard: Dimensions are 20cm long and 15cm wide.
2. Line Body Tag
Standard: Dimensions are 58cm long and 35cm wide.
3. Billboard
Standard: Billboard in the workshop passage, with a uniform height of 150cm, the length of which depends on the actual content, is uniformly mounted with PVC board, black frame, uniform Logo and shading background.
4. Test Equipment Status Identification Plate
Standard: Dimensions are 20cm long and 15cm wide.
Color Management Method
1. Yellow
Standard: The yellow area is used to place goods to be repaired, turnover vehicles, turnover boxes, etc. It can also be used as the identification of the main passage of the workshop.
2. Red
Standard: Red areas are used to locate defective products, garbage cans, fire extinguishers, fire hydrants, dangerous areas, etc.
The AI Workshop 5S Implementation Standards
1. The Ground
Standard: No materials, garbage, scraps of paper should be dropped on the ground, and the ground should be kept clean during working hours. Clean the corner areas of the workshop regularly (at least once every three days), such as fire extinguishers and under the shelves.
2. Equipment Maintenance
Standard: The equipment should be maintained after work every day, and the surface of the equipment should be kept clean with a towel so that no obvious dust can be felt by hand. The air conditioning and shelves of the workshop should be maintained at least once every three days.
3. Material Placement
Standard: Materials should be uniformly and neatly placed on the shelf, different materials should be placed separately, and they should not be mixed, with accurate material identification. When the shelf is not in use, corresponding dustproof measures should be taken.
4. Maintenance Area
Standard: During maintenance work, the top plate of the desktop should not be placed in disorder but should be placed neatly on the L-frame, and the maintenance records should be updated in time. When the maintenance platform is not in use, the power supply of the lighting lamp should be turned off, and the garbage dropped from the ground in the maintenance area should be cleaned up in time.
5. Operation Area
Standard: Earplugs should be worn during operation, and the operation should be carried out according to the requirements of the operation instruction. The desktop should be placed neatly, and the garbage left by the unpacked box and the board to be AI should be placed separately, not together. The electrostatic skin of the desktop is grounded.
6. Checklist
Standard: Routine checklist should be checked before starting up every morning. Check the temperature and humidity meter at 9: 00 a.m. and 3: 00 p.m. every day, and make a temperature and humidity curve.
7. Placing Turnover Cars in Semi-finished Products Area
Standard: When not in use, the turnover truck should be placed in the designated area, keeping the principle of being parallel or symmetrical with the designated area, and it should not be skewed, beyond the planned area or pressed against the line.
8. Placement of Empty Turnover Boxes
Standard: Turnover boxes (including empty boxes and in-use ones) should be placed in the planning area, aligned by the outer yellow line, with a height limit of 2 floors.
9. Garbage Bin Area
Standard: Garbage bins should be cleaned regularly. The garbage should not fall on the ground. The garbage in the bins should not exceed the horizontal line of the garbage bins, and the garbage should be cleaned in time when it is full. Towels should be thoroughly cleaned once a day after 5S cleaning.
10. PCB Temporary Release Area
Standard: The board height in the temporary storage area is limited to 2 floors. The unpacked board cannot be directly placed on the carton but should be put back into the turnover box again, and then taken out when it is used.
11. Riveting Machine Area
Standard: The materials in the material box on the desktop should be clearly marked, and the physical objects should be consistent with the marks. Pay attention to 5S on the desktop when it is not working, and irrelevant items should not appear on the desktop.
12. Loading Area
Standard: Because there are many pins in the feeding area, it needs to be especially helpful for cleaning the ground, which should be cleaned every hour.
SMT Workshop 5S Implementation Standards
1. The Ground
Standard: No materials, garbage, scraps of paper should be dropped on the ground, and there should be no stains on the ground. The ground should be kept clean during working hours. Clean the corner areas of the workshop regularly (at least once every three days), such as fire extinguishers and under the shelves.
2. Equipment Maintenance
Standard: The equipment should be maintained after work every day, and the surface of the equipment should be kept clean with a towel so that no obvious dust can be felt by hand. The air conditioning and shelves of the workshop should be maintained at least once every three days.
3. SMT Material Preparation Rack
Standard: The material preparation rack should be placed in the planned area after the materials are prepared, and documents such as BOM and other items cannot be placed on Feida.
4. Temporary Discharge Area of SMT Tray
Standard: The number of trays in each compartment on the cabinet is limited to 10 trays. The trays in each compartment should be placed neatly and marked with materials. The use of trays should follow the principle of first in, first out.
5. Semi-finished Product Placement Area
Standard: Semi-finished products in the material preparation area should be uniformly placed on the vehicle, and placed neatly by the outer yellow line. Semi-finished products in the non-material preparation area are placed on the ground, uniformly aligned against the wall, and about 10cm apart between different models.
6. Red Glue/Silk Screen Brushing Area
Standard: During the operation, the boards should be placed on the L-frame piece by piece, not directly on the desktop. Due to its nature, special attention should be paid to the cleanliness of the desktop in this area.
7. Connecting Station
Standard: The boards on the L-rack should be placed according to the standard in the figure, and the reports on the table should be updated in time.
8. Post of Visual Inspection
Standard: Except for L-frame, transparent glue, distribution card and distribution card, no other items can be placed on the desktop in the visual inspection area. The above items should be placed according to the specified positioning.
9. Steel Mesh Placement Area
Standard: Steel nets should be placed in one-to-one correspondence according to the numbers on the form. Steel nets in each grid should be placed neatly and cleaned up after use.
10. Freezer
Standard: The use of red glue and solder paste in the freezer should follow the principle of first-in, first-out, and the red glue should be placed in the steel ring in order. When it is taken out for use, it is necessary to register and check the number to ensure that the data on the card is consistent with the actual data. At the same time, the temperature and humidity should be well controlled, and regular spot check records should be made.
11. Thawing Area
Standard: The unfrozen red gum and solder paste should be placed in the designated area, not at will, and the spot check record should be made.
12. Pick-up Belt with Dustbin
Standard: The material belt in the dustbin should be cleaned every two hours, and the material belt should not exceed the dustbin. If any material belt exceeds the dustbin, it should be sorted out in time to avoid leaking out of the dustbin.
13. Sitting Posture
Standard: When operators operate, stools should be uniformly close to the yellow line and parallel to the yellow line. When leaving the operation area, it is necessary to return the stool to its place and approach the connecting platform uniformly.
Standards for 5S Implementation in MI Workshop
1. Production Information Billboard
Standard: The daily production situation on the board should be updated in time, the production capacity of each hour should be updated within half an hour, and the skill matrix should be updated once a month.
2. Filing Cabinet
Standard: Materials and PCB boards are not allowed to be placed in the filing cabinet. SOP, reports, accessories, notebooks, calculators can be placed. All placed items should be clearly positioned and marked and placed according to the marked contents.
3. Placing the Turnover Car in the Fixture Section
Standard: Only one turnover car can be placed in this area. When there is only the last box of the board in this car, the material clerk can come from SMT to get the board. After changing the turnover car, the turnover car with the empty box should be pulled to the AI workshop immediately. The turnover car should be placed according to the positioning, and the line should not be pressed.
4. Hanging of SOP, Grape Cards and Brand Names
Standard: Grape cards are hung on the left side of the corresponding area of each station. The factory brand is hung in the middle, and SOP is hung on the right side. It is hung strictly according to the positioning points.
5. Electrostatic Bracelet Wear
Standard: The electrostatic bracelet is worn too loosely, and the metal surface is not completely in contact with the skin, so the electrostatic grounding effect cannot be achieved. The electrostatic bracelet should be properly worn at the fixed station, and the spot check should be carried out in time (to ensure that it is in good condition and grounded). The mobile personnel on-site should wear electrostatic gloves.
6. Turnover Box Handling
Standard: Dragging the turnover box will cause the materials in the turnover box to collide, and at the same time, it is easy to abrade and damage the floor. The turnover box should be lifted and transported or checked by the turnover car to avoid the vibration and wear caused by the direct friction between the turnover box and the ground.
7. Placement of Tools
Standard: Use foam to carve out models of tools needed for daily production, such as brushes, scissors and fix them in a fool-proof manner. Put the tools to slide, and place them according to the tracks.
8. Material Identification
Standard: For the materials whose thread body is in use, each material has at least one material identification, which needs to be printed by computer and cannot be changed manually.
9. Working Instruction
Standard: Each job post needs to be provided with an operation instruction, and no job can be done at the station without an operation instruction, except for new employees who have just come in to study.
10. Form Update
Standard: The routine checklist of the wire body that needs to be updated every day should be completed before 9: 00 a.m. on the same day, such as the routine checklist of the electrostatic bracelet, maintenance list of the assembly line, maintenance list of soldering iron, ICT maintenance list, FCT maintenance list. The grape card should be updated before the end of the day, and can't be delayed until the next day.
11. PCB Placement
Standard: PCB boards that are too late for operation should be picked up and neatly placed on the L-frame, and illegal operations such as overlapping, pushing, throwing and dropping are not allowed, which may easily lead to bad phenomena such as pad cracks, patches and components falling off, which will bring hidden dangers to the quality.
12. Chemical Control
Standard: Use the designated container to place chemicals, and make a good mark. It is easy for others to drink and misuse chemicals such as plate washing water and moistureproof oil in beverage bottles, endangering personal safety.
13. Wrapping the Power Cord
Standard: The power cables of all kinds of power instruments and equipment are placed in disorder, which is easy to contact with the human body, and there is a potential safety hazard. They should be folded and neatly tied with cable ties to fix the power cables.
14. Soldering Iron, Batch Management
The temperature and batch parameters of soldering iron can't be adjusted privately but should be adjusted by professional spot check personnel to avoid poor operation quality caused by too high or too low parameters. If any abnormality is found, the equipment management personnel should be informed for adjustment or maintenance.
15. Material Management
Standard: Good materials should be separated by different black boxes, and cannot be mixed. The height limit of the digital tube is 10 floors, and that of the relay is 6 floors. The defective products should be put in red material boxes, which can be put together. The defective products (including defective boards) should be cleaned up before the end of the day.
16. Assembly Line Maintenance
Standard: The assembly line needs to be maintained after work every day, with the help of towels and rags. Towels are mainly used to clean the dust on the surface of the equipment, and cannot be used to clean the oil in the equipment. A rag is used to clean the stains in the equipment that are difficult to clean, such as oil stains. Towels should be cleaned after use and hung in the designated area.
17. Place Items on Site.
Standard: On-site articles should be placed in accordance with the principle of "three-set", that is, there should be clear positioning (L-frame, soldering iron, turnover box, etc. should be placed in the positioned area, but not beyond the area or pressing the line), and there should be signs. The number of articles placed should not exceed the standard (the upper limit of the L-frame is 8 pieces), and large materials should not be placed on stools.
18. Use of Towels and Rags
Standard: Towels can only clean the dust on the surface of the equipment, but can't clean the dirt that is difficult to clean, such as oil stains. You can use a rag to clean the oil stains.
19. Placing Large Materials
Standard: The height of large digital tubes is limited to 10 floors, and that of transformers and relays is limited to 6 floors. Garbage in garbage bins should be recycled in time.
20. Temporary Storage Area and Mantissa of Finished Products at the Back of MI
Standard: The temporary storage area at the rear section of the MI line body is divided into 8 grids. If any finished products are temporarily not put in storage due to abnormality, they should be placed in the positioning area, and the line should not be pressed or placed on the channel, with a height limit of 6 floors, which should be placed neatly. The boards in the mantissa area should be cleaned up on the same day.
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