3. PCBU
PCBU
Page 3
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
I will not scatter things around
5S Pledge
I will not get things dirty or spill
I will rewrite things that have got erased
I will set right, things that have come down
I will keep my workplace / station clean
I will remove unwanted material from workplace / station.
4. PCBU
PCBU
Page 4
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Remove all unwanted material with Red Tag
Rule 1
1S
DONTS
DOS
5. PCBU
PCBU
Page 5
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Keep floor dry and clean (No oily stain marks
and wet floor) , no improper epoxy coating
Rule 2
1S
DONTS
DOS
6. PCBU
PCBU
Page 6
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Daily 5S audit and 5S drill
Rule 3
DOS
1S
7. PCBU
PCBU
Page 7
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Daily cleaning of shop floor toilet as per
planned schedule displayed in toilet
Rule 4
DONTS
DOS
1S
8. PCBU
PCBU
Page 8
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Do not keep material (Parts, Tools, Hand-gloves,
Fasteners, Packing material etc.) on floor.
Rule 5
DONTS
DOS
1S
9. PCBU
PCBU
Page 9
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Tool Parking in proper place
Rule 6
DONTS
DOS
2S
10. PCBU
PCBU
Page 10
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Do not keep material on top of the rack, for manual
handling total height should not exceed 1.5m
Rule 7
DONTS
DOS
2S
11. PCBU
PCBU
Page 11
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Ensure dust free machine/fixture/table/control
panel/ inclined columns of structure etc
Rule 8
DONTS
DOS
2S
12. PCBU
PCBU
Page 12
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Use Personal Protective Equipment (PPE) as
displayed on work station / section
Rule 9
DOS
Rubber Glove
Safety Shoes
Helmet
Goggle
Ear Plugs
Hand Sleeve
Hand Gloves
Mask
2S
13. PCBU
PCBU
Page 13
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Keep rejected material with red tag on
standard rejection table
Rule 10
DONTS
DOS
2S
14. PCBU
PCBU
Page 14
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Place marked for everything and everything at
its place
Rule 11
DONTS
DOS
2S
15. PCBU
PCBU
Page 15
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Heading / Sticker ( Part no / part name) for
each item
Rule 12
DONTS
DOS
2S
16. PCBU
PCBU
Page 16
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Electrical panel / boards / switches with proper
name and cover
Rule 13
DONTS
DOS
2S
17. PCBU
PCBU
Page 17
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Use vertical space wherever possible, with
proper handling by mechanized equipments
Rule 14
DONTS
DOS
2S
18. PCBU
PCBU
Page 18
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Keep Fixture/Tool/Gauges/Gun/Equipment of
own work station clean
Rule 15
DONTS
DOS
3S
19. PCBU
PCBU
Page 19
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Standard floor marking for each moveable
item.
Rule 16
DONTS
DOS
3S
20. PCBU
PCBU
Page 20
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
All line side trolleys to be painted in white
color
Rule 17
DONTS
DOS
3S
21. PCBU
PCBU
Page 21
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Display standard format / paper at proper
place. No loose paper on wall / glass / column
Rule 18
DONTS
DOS
3S
22. PCBU
PCBU
Page 22
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Paint all critical machines/ CTQ Trolleys (Amber color)
fixtures/railings etc
Rule 19
DONTS
DOS
3S
23. PCBU
PCBU
Page 23
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Ensure proper natural light, required lux
intensity at workplace and storage place
Rule 20
DONTS
DOS
3S
24. PCBU
PCBU
Page 24
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Neat and clean office with Std file stickers ,
labels , floor marking etc
Rule 21
DONTS
DOS
3S
25. PCBU
PCBU
Page 25
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Use Standard Waste bins with appropriate
stickers
Rule 22
DONTS
DOS
4S
26. PCBU
PCBU
Page 26
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Sr. no.
1
1
2
3
4
5
6
7
8
9
ISO/TS
16949
ISO
14001
OHSAS
18001
ME- BIQ Team Vikram Sinha, Head Car plant
PREPARED BY
Gauri Muttagi
1. Color - Dark Blue
2. Strip Width - 20mm
APPROVED BY
REVIEWED & ISSUE CONTROLLED BY
1. Color - Zebra black on Yellow
2. Strip Width - 40mm
1. Color - Yellow
2. Strip Width - 40mm
1. Color - Red
2. Strip Width - 40mm
Item
Gangway, Walk way & Zebra
Crossing
Dangerous & Moving
equipment
Station 's Pitch
Floor Painting
Floor Painting- Coveyor side
work area
1. Color - Dark Blue
2. Strip Width - 40mm
Scrap Stand, Dust Bins etc
floor marking
Equipment Layout -Fixed
(Machine, Racks, Stands, etc)
Equipment Layout -Movable
(Stabiliser, Power Pack, other
machine accessories etc))
Storage floor marking
(Trollies, Racks, Stands etc)
1. Color - Dark Blue
2. Strip Width - 40mm
Date 9/2/2011
Page Number 2
A. Floor, line side storage area:
1. Color: Light grey color
TATA MOTORS
LIMITED.
PCBU, Pune
Drawing Specifications
STANDARDS FOR
FLOOR MARKING
Document No
Rev. No. 0
A. Coveyor side work area:
1. Color: Light green
Wait Watch & Go symbol
1. Radius - 300mm
2. Using Standard template
3. Required before zebra crossing
A. Gangway:
1. Width -3000mm
2. Color - Light Gray
B. Red Strip:
1. Width - 100 mm
2. Color - Red
C. Walk Way:
1. Width - 600 mm
2. Color - Light Green
D. Zebra Strip:
1. Color - Black in Yellow
2. Passage Width - 600mm
150mm
150mm
Standard for Floor Marking 4S
27. PCBU
PCBU
Page 27
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Colour Codification Colour Name Description for Application
Green Water
Light Blue Air
Silver Gray Steam
Purple Acids
White Oxygen
Brown Flammable oils / Liquids
Yellow Gas
Standardization of Colour coding for Pipe
Lines/Containers as per IS 2379:1990
Arrow should be marked to indicate the direction of Flow. Colour --
- Yellow
And Opening /Closing position of Valves
4S
Standardization
29. PCBU
PCBU
Page 29
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Level 1
1. All unnecessary parts or
materials, pieces of
equipment, tooling,
unused trolleys etc. are
removed.
2. Invalid documents and
old records are disposed
off.
3. Floors are clean, dry and
safe. All aisles are free of
obstruction
Physical condition
1. All shelves and items in
storage and use are
labelled clearly.
2. Dividing lines are all
clear.
3. Storage of tooling is well
set for ease of extraction
and return.
4. All defective parts can
be seen at a glance.
5. Valid process documents
are kept neatly in
identified places.
Retention periods for
records are defined
Visual Control
30. PCBU
PCBU
Page 30
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
1. All machines, work
areas, equipment, and
tooling, without
exception, are clean and
tidy.
2. All dirt and dust
removed from shelves,
work-tables, etc.
Physical condition
1. Checklists for cleaning
are displayed, easily
understood, and
practised by all
personnel.
2. Cleaning and checking
are regarded as one and
the same thing.
3. Sweeping and wiping are
habitual activities. Floor
is always clean and
shining
Visual Control
Level 2
31. PCBU
PCBU
Page 31
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
1. Point of storage of
tooling in regular use is
established, and
organised by
shape/colour, near
the workplace.
2. Outlines show what goes
where.
3. All measures taken to
protect inspection
devices or any other
devices those in use.
Physical condition
1. Everybody sticks to the
rules.
2. Colour is added to the
workplace.
3. Materials storage,
lubricating oils, coolants,
tooling, etc. are
organised by colour.
4. Order is restored
quickly.
Visual Control
Level 3
32. PCBU
PCBU
Page 32
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
1. Attractive work areas.
There is a pleasant and
enthusiastic atmosphere.
2. Intensity of illumination
is appropriate. Everyone
strives to be punctual.
All personnel act
promptly and act
together taking 5S to a
higher level.
3. Cleanliness is applied to
dirt, and orderliness to
disorder to maintain a
rating
Physical condition
1. Departmental
performance and even
minor abnormalities can
be seen without
explanation.
2. Visible signs of daily
improvements. System
established and
practised daily.
3. Five-minute-5S drills
twice in a working shift.
Everything is in its place,
and there is a place for
everything.
Visual Control
Level 4
33. PCBU
PCBU
Page 33
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Place for every thing and
every thing is at its place,
clean and shining and
standardized Workplace ,
Station , Office etc. Sufficient
lux level.
Physical condition
Maintain – Sustain – Audit
rating 5S level achieved
across the shop, Disciplined
and motivated workforce.
Visual Control
Level 5
34. PCBU
PCBU
Page 34
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix I – Lux level - Area / Activities
35. PCBU
PCBU
Page 35
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix I – Lux level - Area / Activities
36. PCBU
PCBU
Page 36
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix II – 5S Check sheet Non Manufacturing
37. PCBU
PCBU
Page 37
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix II – 5S Check sheet Non Manufacturing
38. PCBU
PCBU
Page 38
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix II – 5S Check sheet Non Manufacturing
39. PCBU
PCBU
Page 39
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix III – 5S Check sheet Manufacturing
40. PCBU
PCBU
Page 40
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix III – 5S Check sheet Manufacturing
41. PCBU
PCBU
Page 41
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Appendix III – 5S Check sheet Manufacturing
42. PCBU
PCBU
Page 42
WCQ
WCQ
5S Rule Book
5S Rule Book
TATA Motors
TATA Motors June 2011
June 2011
Target 5S level to
achieve within shop
and outside shop
Benchmark – JLR Shop
5S is not a one time activity, it’s a
continuous improvement
process.
No TPM, TQM, TPS..LEAN is
possible without 5S
5S….. is a way of life.
