5S Manual for Staffs-EN

M LEveryone, Everywhere, Every level, Every time. Please leave us a like on our Facebook page. HT 5S Manual for Staffs Mep Hexa ( Thailand ) Co., Ltd.

Mep Hexa ( Thailand ) Co., Ltd. are aware of the important of work quality, staff’s life quality, lose or waste elimination. Therefore, we use 5S system to increase the efficiency and effectiveness of the working procedure. We hope this 5S manual will be of use to the reader as much as possible. For the most effective and most efficiency methods to comply with company policies. Prepared by 5S committee members

History of Mep Hexa ( Thailand ) Co., Ltd. 6 5S structure and responsible area 7 5S policies and purpose of 5S activities 8 5S definition 9 Benefit of doing 5S 10 Key factor for the success of doing 5S 11-12 Success & Failure in 5S activities 13 Key of S - Seiri is to reduce lose 14 Key of S - Seiton 15 Purpose of doing S- Seiton 16 Key of S - Seisou 17 How to use red tag technique 18 Definition of Muda, Mura, Muri 19

Example for Muda, Mura, Muri 21 Employees Housing Contest project 22 Rules and criteria for Employees Housing Contest 23 Reward for Employee Housing Contest project 24 Criteria for auditing 25 5S system auditing 26 5S area auditing form 27-29 5S activities success audit 30 3 Levels of auditing 31-33 Organization standard 34-35 Public relation team 36-37 5S activities operation of all 4 teams 38 Providers of Academic team 39 Providers of Auditor team 40 Providers of Standard team 41 Providers of Public relation team 42

Mep Hexa ( Thailand ) Co., Ltd. Page 6 In December 1988 We established Hexa Color (Thailand) Ltd. in Yannawa District of Bangkok which have a purpose to do a business of PS ABS coloring, Master batch, and Dry powder for all type of Thermo Plastic. In 1993, the company therefore moved its production base to 102 Moo 5, Wellgrow Industrial Estate, Bangna-Trad Road KM 36, Bangsamak, Bangpakong, Chachoengsao 24180, with more than 10 rai of total area, and its registered capital was added as 112 million baht. In 2001, we has changed our shareholder structure and also changed our company name into Mep Hexa ( Thailand ) Co., Ltd.

Page 7 5S secretary 5S leader 5S advisor 5S committee members Public relation team Academic team Standard team Auditor team Leader level 5S area leader 5S area leader assistant Total area 22,056.44 square meters.

5S policies of company Page 8 Purpose of 5S activities 1. Supporting 5S into use, and to comply with the international standard. 2. Emphasize the discipline with all level of staff. 3. To support safety within workplaces. 4. To increase morals and happy working environment. 5. To meet with internal/external customer’s satisfactory by operate with 5S system.

5S definition Page 9 5S is the abbreviation from Japanese word in English (Romaji), it is easy to use and remember which is the following word: Practices that MHTL use as a guideline. Seiri : Reduce waste Seiketsu : Have right amount of needed things and steps Seiton : Increase efficiency : Reduce inconsistency : Improve working : Continuously doing the first 3 ส process to be easy and fast steps of 5S to build up discipline Shitsuke Seisou : Increase efficiency : Self improving, developing : Improve working process leadership to be easy and fast : Continuously keep the standard

Benefit of doing 5S Page 10 1. Good working environment can increase staff’s morals. 5S has the value of developing personnel discipline, which is the root 2. Reduce accident within the work. of a quality system, because it is an activity that encourages 3. Reduce waste of over purchasing the material. teamwork, is simple, and doesn’t make staff feel that disciples are a burden. It has a benefit to the organization, as the follows: 4. Reduce lost of material, tools or other equipment. 5. Have more working space because the elimination of unneeded material. 6. Have more convenient, and able to work faster. 7. Workplaces are clean, tidy, build up customer’s satisfactory and trust. 8. Staff have more teamwork. 9. Staff have the feeling of organization ownership.

Key factor for the success of doing 5S Page 11 There are many related factor for the success of doing 5S, but it have 2 keys factor which is 1. Personnel and 2. Operation which is the most important factor for the success of doing 5S. 1. Personnel 1.1 Top management 1.1.1 They have to focus and truly support 5S activity as a part of usual work. 1.1.2 They must devoted and participate in the activity, such as, be the 5S committee chairman and continuously follow-up on the result. 1.1.3 Must perform the following duties: 1. Behave as role model for doing 5S, such as, participate in Seiri and Seisou together with workers. 2. Continuously inspect 5S operation of subordinate. 3. Giving complement to the section.s that have good result of 5S. 1.2 Workers 1.2.1 Everyone have to understand about principle, steps and how to doing 5S activity. 1.2.2 Everyone have to participate in 5S activity. (No observer)

2. Operation factor Page12 2.1 There should be training to build up an understanding of doing 5S activity for every person within sections, and provide field study that can be an example to us, and solve all the questions about why we have to do 5S activities. 2.2 Setting standard, and raise it to a higher standard. 2.3 Continuous evaluation, and have a 5S process report system to inform all related people. 2.4 Provide activity that encourages staff to continuously do 5S activity, such as, periodically 5S area auditing by management, Morning Rally without advance notice, management will give a remark or warning symbol, for example, attach a red bow to the desk that didn’t doing 5S to let the desk owner improve it. 2.5 Doing 5S activity along with other activity, such as, Kaizen activity or Suggestion activity. The most important part is a continuous effort to do better than yesterday, and make tomorrow better than today. wO R K

Success / Failure Page 13 5S activity successfulness is depend on someone, but it depend on everyone. “In the other hand, 5S can fail if someone in the organization didn’t understand or didn’t cooperate with 5S activity.”

Key of S - Seiri is to reduce lose Page 14 Key factor for sorting things, tools and equipment. Things not in the daily use is unneeded things. The amount the excess daily needs is unneeded things. How to identify unused things: Consider based on frequency of use. • Things that didn’t use more than 1 Year: Dispose or remove from working space. • Use 1 time / 6 months to 1 year : placing far from working space. • Use 1 time / 1-6 เดือน: placing / keep near working space. • Use 1 time / week: placing / keep in working space. • Use daily: placing / keep in working space. • Use every hour: placing in the place that can promptly reach. Insufficient important or needed things must be promptly restock and broken things must be promptly repair. Onsite operation Preparation steps(record present status) 1. Define area / location that need to improve. 2. Take a before/after photo of such area. 3. Find waste of material, parts within finished goods production process.

Key of S - Seiton Page 15 Increase the efficiency of working process. (Speed) S- Seiton means sorting the category and location arrangement have to be well planed and operator within the organization must know where the needed things are by indicate with indicator. It is comply to \"Easy to find, Know when its lost, Looks beautiful”. Working process of S - Seiton 1. Properly store the things or have an indicator. 2. Return the things to its original place when done using them. 3. Placing the things that frequency use within the reach. 4. Sort the things into category. Working process of S - Seiton 1. Make diagram to indicate the specific place of things within the area, and have to link with the smallest unit of things 2. Clearly specify placement area to prevent the things from mixed up. 3. Prepare name tag according to the planed system. 4. Arrange things according to the diagram by placing the most use things within reach or far from reach based on the frequency of use.

Page 16 Purpose of doing “S - Seiton” S-Seiton All level staff should specify the name, location 1. To reduce time wasting on searching things. and quantity. 2. To reduce document and tools lost. 3. To increase work efficiency and reduce working time. 4. To organized the workplaces to be in a safety manner. Basic rule of creating convenient “ Basic subject that should be remember” 3 steps rule to creating convenient - Where do you keep it?…… (Specify the location) - What did you keep?…… (Specify the name) - How many do you keep?…..(Specify the quantity) Make an indicator to ensure that staff understand and able to answer the 3 above question.

Key of S - Seisou Page 17 Inspection S – Seisou means continuously take care about cleanliness of all working area, as well as maintain the condition of tools to be in a ready to use condition by doing as the follows: 1. Specify area and machinery responsible person as in the plan. 2. Learn the details of area and machinery cleaning process to prevent the damage. 3. Prepare a cleaning plan during the work, in each shift, daily plan, monthly plan and annual plan. Cleaning process Click here 1. Assign an area Add text 2. Learning the process 3. Set the time 4. Set the details 5. Use suitable tools 6. Do it everyday (inspect for abnormality)

How to use red tag technique Page18 It is the method to specify “unneeded things” or “misplace things” within the workplaces. What kind of things we should put a red tag on? Unneeded things Machinery Machine components Shelve The spot that should be organized. Documents 1. On the desk or drawer of each person. Stationary 2. Document cabinet / Storage / Shelve. 3. Around the desk. 4. Storage room. 5. Blind spots in both internal/external of workplaces. 6. Area of workplaces, including the ceiling. 7. Rules notification board.

Definition of Muda Mura Muri Page 19 無駄 (Muda) 斑 (Mura) 無理 (Muri) • In English it is “Waste” or • In English it is • In English it is “Overburden” or “Lose”. “Unevenness” or working in excessive working. inconsistency condition. • This subject make the cost • This subject means staff done a of production get higher, • This subject lead to work more than they capable of, but didn’t increase the inconsistency of the product work overload or difficult work that product or have more quality, makes product or have a low chance of success which efficiency, and didn’t services to not meet with lead to mistakes, ineffective work, increase the value of standard which may occur injury or accident that stop the work product or services which from unclear working or causing stress. can be in various aspect, process, frequently change such as, waiting, moving, the working process, changes, produce a new inconsistency of work one, arguing, etc. amount in each day.

Muda Mura Muri relation Page 20

Muda Mura Muri Example Page 21

Employees Housing Contest Page 22 Starting from project naming award, and the chosen name is “Happiness from discipline in 5S” Mr. Richawut Saemto ID 0893 Production 2 receive 1,000.- baht as a reward. The winner

Page 23 Rules and criteria for Employees Housing Contest Rules and criteria for considering the “Happiness from discipline in 5S” project are the following: • In the case of families, one project can be sent per house/rent room. • In the case of single / live alone, 1 project per house /rent room. • Required evidence Photo before, during and after, or video before, during and after (total length does not exceed 3 minutes) • The duration of the competition is from June to September 2022. • Period for consideration October to November and giving reward on December 2022. • What 5S principles do you use to improve it? For example, 5s, visual system, Kaizen, Lean • Submitting evidence via google form. • Employees at all levels can be submitted to this project contest.

Rewards for Employees Housing Contest Page 24 Rewards • 1ST prize 3,000 Baht • 2ND prize 2,000 Baht • 3RD prize 1,000 Baht • Consolation prize 500Baht. (limit 10 prizes) Criteria to choosing a judge from all 4 teams that will be judging “Happiness from discipline in 5S” project. • Any committee submitting a project has no right to be a judge. • 2 persons from each team / reserve 1 person from each team. • All teams have to submit the judge name before 19TH May, 2022. 5S committee vice leader request each team to review the responsible content in 5S manual and send to center for preparing the complete 5S manual, this 5S manual shall be key instrument for our staff to adapting the 5S principle to improve their house in this contest.

Criteria for auditing Page 25 Auditing manual will specify the details of 5S What is 5S auditing? auditing based on the central standard, common area standard, specific area standard and other standard.

5S system auditing Page 26 5S system auditing purpose is to motivating continuously 5S operation by using 5S area auditing form to create competition within the organization, the audit have 3 levels as the follows: 1. Staff or area owner audit by themselves (Self Audit) 2. Audit by committee (Committee audit) 3. Audit by top management (Top Management Audit) Criteria point that use in auditing 1. Self Audit must have point above 90% to pass the criteria. “Pass” get 1 point, “Not pass” get 0 point. 2. Committee audit have the following criteria: - In each box will have 1 point as a full score. - Found 5S nonconformity in some area will get 0.5 point, all area will get 0 point. It can see from an example of 5S area auditing form in the next page.

5S area auditing form Page 27

5S area auditing form Page 28

5S area auditing form Page 29 In each audit we calculate the score in to 100% must have score not below 85 % to pass the audit. If the score is below 85% more than 2 times in a row, that area will be a topic in 5S meeting to discuss about the root cause why it didn’t pass the criteria.

5S activities success audit Page 30 1ST level is Self Audit Area leader will collect the audit score in each month and record it on SERVER2. 2ND level is Committee Audit Audit team will do 5S auditing and will hold the meeting for summarize the good point, bad point, suggestion, subject need to improve to comply with the laws of each area. Then return auditing form with the audit results to area leader within 3 working days after audit for area leader to record in SERVER2. 3RD level is Top Management Audit Top Management or The president will audit 2 times/year, audit team will do onsite audit for area leader to sign for acknowledgement and store after top management audit is finished.

Page 31 1ST level Self Audit Target of audit 1. The score must be 90% or above in each audit. 2. Audit every month. Audit methods 1. Area leader audit by using self audit form. 2. Thoroughly understand the topic of audit standard. 3. Inspect the previous improvement from area that have a comment. 4. Strictly audit according to the criteria. 5. Audit frequency is once a month based on 5S audit standard.

Page 32 2ND level Committee Audit Target of audit 1. 100% audit in all area. 2. Audit score in each area must be 85% or above. Audit methods 1. Audit team audit by using 5S area audit form. 2. Thoroughly understand the topic of audit standard and criteria of giving a score. 3. Auditor mustn’t audit their own area. 4. Strictly audit according to the criteria. 5. Audit frequency is 1 time/ 2 months based on 5S audit standard.

Page 33 3RD level Top Management Audit Target of audit 1. 100% audit in all area. Audit methods 1. Top management audit by using audit form on Server2 in 5S Management System Audit folder. 2. Emphasize on build up motivation, and promote cooperation of all staff within the organization. 3. Audit frequency is 2 times / year based on 5S audit standard.

Organization standard Page 34 5S standard divided into 2 standards which is: 2. 5S area standard: 1. 5S central standard: All person or section able It is the standard in specific area, such as, LPG storage standard, HG area standard, to use it as a guideline, such as, Stamping room standard, PR1 are Working desk standard standard. Computer standard Fire extinguisher standard Canteen standard Toilet standard Details of the standards is here. ������������������

1. Prepare central standard and giving an advice about how to prepare area standards. Page 35 2. Coordinating to put standard into action. Standard 3. Collecting data to revise the standard to be up to date. team 4. Be the leader in meeting of drafting the central standard. Central standard Area standard

Public relations team Page 36 1.Publicize and distributing the news from 5S slogan standard team, academic team and audit team to Clean factory all staff. Bright atmosphere 2. Provide happiness and fun to motivating the Everyone is safe staff to participate in 5S activity. Unite to do 5S 3.Motivate staff to discipline with 5S culture.

5S meet friends 5S on tour Page 37 This activity will provide staff with 5S knowledge and build up discipline of 5S in the staff. Makes staff to feel fun when participate in 5S activity. Put on public relations sign all around the factory Publicize the news on Facebook Publicize the news to all staff via central board and knowledge sign.

5S activities operation Page 38 of all 4 teams Audit team Public relations team Academic team Standard team 5S slogan Clean factory Bright atmosphere Everyone is safe Unite to do 5S

Providers of Academic team 5S Page 39 5S 5S Mr. Somkiet Mr. Arton (Team leader) Ms. Patsavee Mr. Kunakorn Mr. Pichet Ms. Paphaphint MH T L Mr. Thongchai Ms. Rattana

Page 40 Ms. Kanungnit Ms. Boonruam Mr. Ronnapoom Mr. Saksiam Mrs. Sawing

Page 41 Ms. Sumalee Mr. Jaruwatn (Team leader) Mr. Manoon Mr. Chaiya Ms. Nachanok Ms. Supattra

12 3 4 Providers of Page 42 Public relations team 1. Mr. Chatpisit (Team leader) 2. Mr. Wasan 3. Mr. Thanin 4. Ms. Patcharee 5. Ms. Lalida 56 78 6. Ms. Chutikarn 7. Ms. Vipaporn 8. Ms. Benja