20 Items Marked for 5S Management in Valve Workshop
Mar 31, 2022
General Standards (common in workshops)
Behavior discipline
1. In and out of the Workshop Hall
Standard: When entering and leaving the valve workshop hall, you should close the door behind you. When opening or closing the door, you should gently push it. Do not hit it violently to avoid damaging the glass door.
2. Walking in the Workshop Passage
Standard: Walk in the middle of the passage on the right side of the passage when going to work in the workshop. No frolic or fast running is allowed. More than two people can form a formation and consciously walk in formation.
3. Private Shoe Cabinet
Standard: After changing shoes, the private shoe cabinet should be locked, and the door of the shoe cabinet should be opened at will. If the key of the shoe cabinet falls, it should be registered with the security officer, and the spare key should be obtained to match the lock. The lock of the shoe cabinet should not be broken at will, otherwise, compensation should be made according to the original price.
4. Use of Water Dispenser
Standard: When receiving hot water, be careful to be scalded by hot water. There is hot water in the faucet marked in red on the left. After receiving the water, gently close the drinking cabinet door. In addition, if there is tea in the water cup, don't pour it into the pool, please pour it into the bucket next to it.
5. Cleaning the Ground in the Pantry and Shoe Changing Area
Standard: Snacks, fruit dander, etc. eaten in the pantry should not be thrown on the ground, but should be thrown in the trash can.
6. Books and Periodicals Management in Pantry
Standard: After the books on the book and newspaper shelf are borrowed, they should be neatly placed on the book and newspaper shelf and not taken out of the pantry.
7. Personal Clothing
Standard: You should wear work clothes to work. Do not wear shorts and cropped trousers to enter the workshop, and do not wear jewelry, such as rings, necklaces, earrings, etc. Boys should not wear long hair, and girls should tie their hair tightly in their hats. When entering the workshop, you should wear electrostatic clothes, and the zipper should be pulled to the end.
8. Sitting Posture at Work
Standard: Keep your knees together naturally. Keep your legs upright or on your side. Don't cross your legs. At least two-thirds of the chair is full. The distance between people should be at least 20CM, and the stool should be about 5cm away from the yellow line.
9. Brand
Standard: The brand issued by the company should fill in the above contents according to the requirements, and the handwriting should be neat. In the column of the department, "overseas workshop" should be written uniformly. It is not allowed to scribble on it, and a one-inch photo of the individual should be attached. When working, you should hang the brand on the right side of your corresponding work instruction, and take it back after work.
10. Stool Placement
Standard: When working, the surface formed by the two feet on the outside of the stool should be parallel to the yellow line, and the distance between the feet and the stool should be kept at about 1CM. The yellow line should not be pressed. After work, push the stool into the assembly line and pull it inside. The stool should be close to the trachea below.
11. Towel Cleaning
Standard: Towels should be thoroughly cleaned with washing powder or detergent after 5 seconds every day, and there must be no obvious stains on the cleaned towels.
12. Management of Personal Belongings
Standard: Personal items, such as drinking water, snacks, skincare products should not be brought into the workshop. Don't play mobile phones at work.
13. Management of Company's Distribution of Auxiliary Materials
Standard: Accessories issued by the company, such as electrostatic bracelets, electrostatic gloves, and electrostatic shoes, should be properly kept by themselves. Do not scribble or damage them at will.
14. Operation Process
Standard: Don't talk, laugh and discuss things unrelated to the work content during the work.
Identification Management
1. Material Identification
Standard: The logo is 7.5cm long and 1.5cm wide, and is uniformly placed in the card slot on the front of the material box.
2. Marking on the Assembly Line
Standard: the width of the logo is 1cm, and the length depends on the actual content of the logo. It is stuck in the middle of the positioning line.
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.
Behavior discipline
1. In and out of the Workshop Hall
Standard: When entering and leaving the valve workshop hall, you should close the door behind you. When opening or closing the door, you should gently push it. Do not hit it violently to avoid damaging the glass door.
2. Walking in the Workshop Passage
Standard: Walk in the middle of the passage on the right side of the passage when going to work in the workshop. No frolic or fast running is allowed. More than two people can form a formation and consciously walk in formation.
3. Private Shoe Cabinet
Standard: After changing shoes, the private shoe cabinet should be locked, and the door of the shoe cabinet should be opened at will. If the key of the shoe cabinet falls, it should be registered with the security officer, and the spare key should be obtained to match the lock. The lock of the shoe cabinet should not be broken at will, otherwise, compensation should be made according to the original price.
4. Use of Water Dispenser
Standard: When receiving hot water, be careful to be scalded by hot water. There is hot water in the faucet marked in red on the left. After receiving the water, gently close the drinking cabinet door. In addition, if there is tea in the water cup, don't pour it into the pool, please pour it into the bucket next to it.
5. Cleaning the Ground in the Pantry and Shoe Changing Area
Standard: Snacks, fruit dander, etc. eaten in the pantry should not be thrown on the ground, but should be thrown in the trash can.
6. Books and Periodicals Management in Pantry
Standard: After the books on the book and newspaper shelf are borrowed, they should be neatly placed on the book and newspaper shelf and not taken out of the pantry.
7. Personal Clothing
Standard: You should wear work clothes to work. Do not wear shorts and cropped trousers to enter the workshop, and do not wear jewelry, such as rings, necklaces, earrings, etc. Boys should not wear long hair, and girls should tie their hair tightly in their hats. When entering the workshop, you should wear electrostatic clothes, and the zipper should be pulled to the end.
8. Sitting Posture at Work
Standard: Keep your knees together naturally. Keep your legs upright or on your side. Don't cross your legs. At least two-thirds of the chair is full. The distance between people should be at least 20CM, and the stool should be about 5cm away from the yellow line.
9. Brand
Standard: The brand issued by the company should fill in the above contents according to the requirements, and the handwriting should be neat. In the column of the department, "overseas workshop" should be written uniformly. It is not allowed to scribble on it, and a one-inch photo of the individual should be attached. When working, you should hang the brand on the right side of your corresponding work instruction, and take it back after work.
10. Stool Placement
Standard: When working, the surface formed by the two feet on the outside of the stool should be parallel to the yellow line, and the distance between the feet and the stool should be kept at about 1CM. The yellow line should not be pressed. After work, push the stool into the assembly line and pull it inside. The stool should be close to the trachea below.
11. Towel Cleaning
Standard: Towels should be thoroughly cleaned with washing powder or detergent after 5 seconds every day, and there must be no obvious stains on the cleaned towels.
12. Management of Personal Belongings
Standard: Personal items, such as drinking water, snacks, skincare products should not be brought into the workshop. Don't play mobile phones at work.
13. Management of Company's Distribution of Auxiliary Materials
Standard: Accessories issued by the company, such as electrostatic bracelets, electrostatic gloves, and electrostatic shoes, should be properly kept by themselves. Do not scribble or damage them at will.
14. Operation Process
Standard: Don't talk, laugh and discuss things unrelated to the work content during the work.
Identification Management
1. Material Identification
Standard: The logo is 7.5cm long and 1.5cm wide, and is uniformly placed in the card slot on the front of the material box.
2. Marking on the Assembly Line
Standard: the width of the logo is 1cm, and the length depends on the actual content of the logo. It is stuck in the middle of the positioning line.
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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