Development of industry, Improvement of quality, accuracy, work efficiency

５Ｓ in measuring equipment

Ver.5.1

Measurement is very important to develop plants. I will show you
examples of 5S which fit the field conditions. These make yourmeasurement effective.

Ford Rouge Plant 2005/9

The Toyota Commemorative Museum ofIndustry and Technology 2005/2

Guangzhou Toyota Motor Co., Ltd.（GTMC）
Engine Plant 2007/3

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Contents
 Preface What is 5S in measuring equipment ?

6

 The point of 5S in measuring equipment

8 1.Improvement of 5S in measuringequipment.
 1.1 The necessity of 5S in measuringequipment

11

 1.2 Ideas of arrangement14 1.3 Considering

16

 2.How to place and clean measuring
equipment.
 2.1 Single measuring equipment20

 2.2 A few pieces of measuring equipment 22
 2.3 Many pieces of measuring equipment24

 2.4 Tow-stage type
 2.5 Placing in shelves28

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 2.6 Piling30

 2.7 Electric measuring equipment32

 2.8 All kinds of measuring equipment34

 2.9 Using Vidoma (trade name?)36 2.10 Protecting from dust38

 2.11 Improving magnet stand40

 2.12 Tools type42

 2.13 Pin gauge （single）．

44

 3. Steps of 5S in measuring equipment 3.1 Just 5S,but…．

48

 3.2 Planning steps of 5S50

 Postscript2

Preface What is 5S in measuring
equipment ?
 SeiriThis netprotects
measuringequipmentfrom fall
whenearthquakes
happen.

To get rid of unneeded andbroken items.

 Seiton
To organize the workplace.

 Seisou
To clean carefully Seiketsu
To keep clean

 Shitsuke

A cabinet of measuring equipment
taken measures against earthquakes.

To keep a custom of usingcarefully Measuring equipment are indispensable to making products.
 5S in measuring equipment has a great effect.
3

The points of 5S in measuring equipment

ToTo keep
keep accuracy
accuracy
ToTo work
work easily
easilyTheThe good
good look
look
These
These areare thethe starting
starting points
points forfor
makingmaking products
products andandISO9000/TS16949.
ISO9000/TS16949.
4

1. Improvement of 5S in measuring
equipment
1.1 Organized 5S
1.2 Ideas of arrangement
1.3 Considering

All workers should put organized 5Stechnique to make and keep the 5S likethis photo.
The Deming Prize –winning plant.
Place for measuring equipment
5１．Characteristics of 5S in measuring equipment

1.1 Necessity of organized 5S
Wrong 5S example.
1. Measuring equipment arearranged neatly on whiteclothes while guests
come.
2. The 5S has not been
maintained.
3. These are wrong 5S. 5S
needs techniques andorganized practices.

6

１．Characteristics of 5S in measuring equipment

1.2

Ideas of arrangement
materials

Training oftechniques

Knowledge

Buying fromthe Internet.
Techniques
done by former
workers

Arrangement needed improvement

Fit arrangement
to the workshop

Ideas of arrangement

Looking up newmaterials on catalogues.

personmethods
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１．Characteristics of 5S in measuring equipment

1.3 Considering
Not considered

Considered

1. Doing without thinking
2. Not noticing waste
3. Nobody teaches.

Improving when they got ISO9001
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2. How to place measuring equipment.
I will show you examples of arrangement of measuring equipment.

The 4th Aichi metrology and measurement exhibition in 1995.
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2.How to place measuring equipment.

2.1 placing single measuring equipment
Placing a micrometer

Placing a micrometer on amanufacturing line.

Characteristics

Stable measurement

Cleaning way

Clean the measurement part and the moving part with cloth.

NoticeDo not clamp a micrometer too tight.

A short space of measurement time

Height gauge

Height master
gauge
AnAn example
example ofof placing
placing aa micrometer.
micrometer.

AnAn example
example ofof placing
placing aa micrometer
micrometer onon
aa manufacturing
manufacturing line.
line.
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2.How to place measuring equipment.

2.2 A few pieces of measuring equipment
An example of placing a few pieces ofmeasuring equipment on the line. Up to 5pieces.

 Characteristics
It is easy to pick up
equipment and measure.
 The cleaning way
Clean measuring parts,calibrations and the moving
parts with cloth.
 Notice
Be sure to clean themeasurement table.

The stand is made by a skilled worker before painted.
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2.How to place measuring equipment.

2.3 Many pieces of measuring equipment
An example of measurement in the final process.

 Characteristics
Measuring equipment is set
in order. You can easily findthe equipment you need.

 The cleaning way
Sweep out the whole place
to put on measuringequipment.
Clean the whole gauges.

 Notice
Be sure to put themeasuring equipment on
the appointed place.

122.How to place measuring equipment.

2.4 Tow-stage type
 Characteristics
The fourth leg of this table isdislocated. It is useful tomeasure with many pieces ofmeasuring equipment when you
calibrate measuring equipment.
 The cleaning way
Clean the frame, the revolving
part of the equipment,calibrations with cloth.
 Notice

An example of tow-stage type

When you put the measuring
equipment on the stand, thehandles face the users.
13

2.How to place measuring equipment.

2.5 Placing in shelves
An example of keeping many pieces of measuring
equipment such as a test workshop.

 Characteristics
It costs so much to make acabinet like this photo, but
it is reasonable in all.
 The cleaning way
Clean the equipment caseand the shelves with broom
and cloth.
Do not use an air blow.
 Notice
Label the identifying
numbers on the cabinet
and measuring equipment
and these cases.
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2.How to place measuring equipment.

2.6 PilingAn example of separation with wooden boards.

Not separated

Separated withwooden boards

 Characteristics
It is stable and easy totake it out.

 The cleaning way
Clean the shelves with broom andcloth.
Do not use an air blow.

 Notice
Label identifying numbers
on both shelves andmeasuring equipment.
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2.How to place measuring equipment.

2.7 Electric measuring equipment
An example of cabinet in a lab.

 Characteristics
Leads made into
small loops arestable.
 The cleaning way
Clean with cloth.
Do not use an airblow.
 Notice
Do not bend leads atright angles.

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2.How to place measuring equipment.

2.8 All kinds of measuring equipment

 Characteristics
Clear arrangement.

 The cleaning way
Clean the shelves, theequipment, themoving part of theequipment with cloth.
Do not use an airblow.

 Notice
Decide appropriatearrangement of measuring
equipment with thinking
over kinds, characteristics,
frequency in use, andaccuracy of measuring
equipment.
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2.How to place measuring equipment.

2.9 Using Vidoma（trade name?）
Labeling names

 Characteristics
Placing clearly, taking out
easily, and putting easily.
 The cleaning way
Clean the inside of gauges
and the surfaces to reed
the sizes with cloth.
 Notice
Use hard boards aspartitions.

Partition18

2.How to place measuring equipment.

2.10 Protecting from dust
An example of spreading the cutting powder, and the cutting oil over themeasuring equipment.
Labeling
the sizes.

 Characteristics
It can be kept accuracy.
 The cleaning way
Clean the cases and themeasurement face withcloth.

A transparent acrylic case

 Notice
Do not forget to takethe occurrence sourcemeasure.
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2.How to place measuring equipment.

2.11 Improving a magnet standClamp

Remove the part ofmagnet and fix
measuringequipment on thesurface plate.

 Characteristics
It is effective tomeasure the samesizes.

 The cleaning way
Clean the part of themeasurement point
and the glass facewith cloth.

 Notice
Fasten a clamp, firmly.
If you do not do so, thedata is error.

20

2.How to place measuring equipment.

2.12 Tool type
Drop easily！
And break down.

 Characteristics
Small space forputting.

 The cleaning way
Clean the frame, themeasurement face, therevolving part with cloth.

 Notice
Measuring equipment
is broken easily.

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2.How to place measuring equipment.

2.13 Pin gauge（single）

Using small boxes
 Characteristics
Easily making
space to put.

Labeling sizes The cleaning way
Clean the oil dirty
on cases with cloth.

Cutting the top ofthe case

 Notice
Place pin gauges at
the appointed places.
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3. Steps of 5S in measuring equipment

3. Steps of 5S in measuring equipment
3.1 Just 5S in measuring equipment, but…
3.2 Steps○○plant 1st manufacturing workshop

NoticePlease change these steps to be suitable to yourworkshop when you use.
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3. Steps of 5S in measuring equipment
3.1 It is just 5S in measuring equipment ,but….
Well, your products are
defective. They are too small.
Are your measuring
equipment dirty, aren’t
they?

○○plant○○plant 1st
1st manufacturing
manufacturingworkshop
workshopI am sorry！
I will be careful.

,but it is important to do ５Ｓ.
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3. Steps of 5S in measuring equipment

3.2 1st step
 Making an announcement about management policy and goal.
 At Executive meeting, morning meeting, and by notices etc.
 Implementing 5S fully Reducing complaints and increasing work efficiency.
 Making a plan costmaterial、tools、personnel costs, training costs membergroup：8～12 workers
 term
4～12months
 instructing training individually workshop○○plant 1st manufacturing workshop

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3. Steps of 5S in measuring equipment

3.2 2nd step
 Bench mark（for every manufacturing line、every machine、every person）
 Records of the present 5S
 Fixed point photography Taking photos at the same point before and after the improvement.

 Making a list of unneeded items
 Identifying unneeded items and defective products
 Making a total list of unneeded items and defective

 Getting rid of unneeded items
 Eliminating defective products Removing unneeded items to a store houseproducts

Eliminate
unnecessary items.

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3. Steps of 5S in measuring equipment

3.2 3rd step
 Check the process Role of measurement

Does it go well ?

 Effective arrangement to put and take out
measuring equipment
 The Look good

 Clean the process easily
 Specifying locations for cleaning tools near thework places.
 Easily taking waste out No care of getting accuracy of measuring
equipment lower Recording and using the records• Quiet colors

 Quality check• Stable placement

 A history of trouble with the measuring
equipment , etc.

• Eliminating unneeded items
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3. Steps of 5S in measuring equipment

3.2

4th step Do cleaning

Cleaning changes processes.

 Decide the procedure by person
Decide to clean what part of the measuring equipment, when, how,
and make papers with photos.
 Have cleaning tools
Dust cloth、cloth box、brooms、dust box

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3. Steps of 5S in measuring equipment

3.2 ５th step Management of lending
measuring equipment out.
 Putting measuring equipment
name tags on each measuringequipment.
ex.：digital vernier caliper 200mm
 Making a board for putting
measuring equipment name tags.

Measuringequipment
name tag

Board putting
name tags

 A measuring equipment user put
the equipment name tags on theboard.
User’snameUser name
Measuring equipment name tags
which are out on loan.
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3. Steps of 5S in measuring equipment

3.2 6th stepPatrolling on 5S for improvement（There is an example which has been continuing 5S for 15 years.）

 goal Implementing 5S continually and fully member About 5 workers under manager, including office member（1） methods
 Frequency ：three or four times /year Use of check lists, example 3KA
 Examining implemented 5S at a committee or personal instructive meeting afterpatrol30

3. Steps of 5S in measuring equipment

3.2 7th step Examples of 5S competence in measuring equipment for each line , each machine ,each person.
Measuring competence

5S competence

Total competence

You are able to measure with thefollowing measuring equipment
which are in the process you arecharged with and fill in check sheet.
・Vernier caliper
・Micrometer・Dial gauge
・Plug gauge
・Caliper gauge, etc.

You are able to do the following.
・cleaning of the measuring
equipment.
・cleaning of the keeping places.
・check the condition of themeasuring equipment.
・check the regular calibration
label.

・You can teach how to use
measuring equipment.
・ You can teach 5S to otherworkers.
・You can instruct workers withdata.
・You can report, tell, and talkto related workers.

31PostscriptJust 5S of measuring equipment, butI found a thing when I studied measuring error (SN fraction). The dirt on measuring equipment has great
influence on error. 5S of measuring equipment is one of the biggest factors in measurement techniques.
A manager who charges in quality guarantee passed without noticing dirty measuring equipment throughthe plant. Then I found that it is difficult for managers, even they are at high position, to notice somethingout of their special fields. We assume that we have known the roles and how to implement 5S of measuring
equipment, but in fact many workers do not understand them.
I think that 5S is very important because 5S has an influence on quality and work efficiency. I have seen a
lot of plants where workers have measured with dirty and damaged measuring equipment. Then they haveproduced defectives and work efficiency has been down. I think workers should put the techniques of 5S.
I show you typical 5S examples. I wrote this manual for improving 5S techniques in measuring equipment
suited to every company. I would appreciate it if you would refer to this.

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All rights reserved
5S in measuring equipment
Tetsuya Hidaka
Certified measurer（６９６１）
ＪＡＢ commissionedＩＳＯ／ＩＥＣ１７０２５ auditor （ＡＬ００７５）
Certified professional coach by Foundation of Global
Life Learning Center （１１５）dateAchievements
Instructing appropriate measurecontrol places (4)Consulting of acquisition of ISO
9001 accreditation (10)ISO9001 audit (52)the first edition

6/5/1996

Consulting of acquisition of ISO
14001 accreditation (3)4.1

10/9/2006

QS-9000 audit (25)

Publishing house Hidaka Metrology Office
2-1 Tatsumito, Heisakacho,
Nishioshi, Aichi pref. 444-0305
ｔｅｌ 0563-59-7250 ｆａｘ 0563-59-9047
E-mail tetsuya.hidaka@m-hidaka.com

ISO/IEC17025 Technicalaudit(12)Coaching in business
improvements (4)Coaching for passing tests(Energy manager, Engineer)33