1/8

Table of Contents

1. Standardization Purpose

2. Standardization Guide

3. Standard of Line Color

4. Standard of Sticker

5. Standard of Pipe and Tank Color

※ Attachment: VM Guidance

Pohang Works VM Standard

2008. 4 포항제철소 혁신지원그룹 QSS-Master 김종욱

☎ 220-8285011-9389-2249

Preface

To push ahead with 5S we must do the visual management to make it easier for everyone to see and in fact visual management is the real key to the settlement of the 5S. There are a lot of cases where people think that 5S is done only in the factory scope but in reality 5S can be done in the office scope and the seen effect is the same as 5S effect in the factory. Visual management is not an activity to make us look better in front of other people. It is a

method to facilitate other people in seeing problems. This book can help you who already practiced visual management and feel the need to set a clearer purpose and effective standards or you who want to add points you needed in the site and execute the method. Thus, the purpose of visual management standard and guidance is to allow whole member

in the site to be able to share the problems occurred based on the easy-to-understand contents, able to respond quickly and eliminate problems, and to create a vibrant atmosphere in the site.

2008년 4월

혁신지원그룹장 안동모

사내한

본 자료는 회사의 중요한 지적 자산으로서

사장의 사전 승인없이 사외로 반출 할 수 없으며,

그 내용을 복사하거나 외부에 공개, 누설할 수 없습니다.

V M 2008-

Pohang Works Visual Management (VM) Standard

1. Standardization Purpose

a. To avoid unorganized display caused by different method, color, form, and size

used by each department

b. To set standards for Pohang Works VM and common stickers to be used can be

obtained by applying through EP-Supplies Purchasing Application (Printed

Material), Safety Disaster Prevention System (Notice Board)

2. Standardization Guide

a. To set standard for the basic VM color, form, and size

b. Guidance will be made and published for other case-by-case detailed

application method (VM Guidance as reference)

3. Color Standard for Line Painting

Facility Color Code Color Reference Remark

Test Lab Measuring Device Type

White White Name sign

Safety Passage Line 6.4Y 8.4/10.3 Yellow Center line concept

Object Position Line 6.4Y 8.4/10.3 Yellow Name sign

Entrance Sign 6.4Y 8.4/10.3 Yellow Radius sign (Dotted line)

Walking Direction Sign White White Arrow sign

Danger Sign Yellow:6.4Y 8.4/10.3

Black: N 1.0 Yellow-black stripes

Passage

Work Area 0.1G 5.2/6.2 Green Factory floor

Passage 6.8R 4.2/9.7 Clay-red color Passage floor

Warehouse

N 6.5 Gray Warehouse floor

Contents Limitation

Max 7.5R 4.8/12.8 Red

Min 6.4Y 8.4/10.3 Yellow

Line Painting Method

<Rule> - Don’t step or go over the yellow line - Area line is the life line - Draw straight line if possible - Make everything to be easily visible - Make passage line as simple as possible - Minimize angular part - 모퉁이는 직각을 피한다 - Line classified by color

4. Pipe and Tank Color (POSCO Standard)

Liquid & Gas Type Item Classification Color Code Color Reference Remark

Water

Fresh Water, Clean Water, Raw Water, Sea Water, Return Water

10B 6/7 Navy blue (Blue)

※ Attention 1) Facility that

needs heat resistant for over than 150℃ is painted with silver color

2) Machine colors

are painted with semi-matte paint

3) Resin paint is

used for requirements such as oil-proof, waterproof,

and chemical resistance.

Domestic Waste Water N 6.0 Dark Gray

Factory Waste Water 7.5R 3/6 Seal Brown

Air AIR N 9.5 White

기송관 (Air Shoot Pipe) 2.5G 5.5/7 Dark Green

Steam Steam Silver Silver

Gas

O2 10B 8/4 Light Sky Blue

N2, Argon 2.5P 5/6 Purple

COG, Mixed Gas, BFG, LDG, LPG 10YR 7.5/11.5 Yellow

H2 2.5RP 4.5/12 Wine (Purple-red)

Acid, Alkali Acid, Alkali 2.5P 5/6 Eggplant Purple

Oil LUB Oil, Grease Organic Oil 7.5YR 5/6

B-A Oil, Grease Organic Oil 2.5YR 5/5.5

Electricity Conduit 2.5YR 7/6 Dark Orange

Outdoor Tank, Holder General Painting 10YR 9/3.5 Beige

Heat Resistance Painting Silver Silver

Manhole & Pit Cover

Waste oil N 1.0 Black

Power Cable 2.5YR 7/6 Dark Orange

Communication Cable 10GY 6/10

Power Cable + Water N 6.5 Gray

Classification

Standard(mm) Illustration

A B Arrow Mark Right Direction Left Direction

Contents

200

100

ⓐ 37

ⓑ 109

ⓒ 41

ⓓ 20

120

60

ⓐ 22

ⓑ 64

ⓒ 24

ⓓ 12 Remark

80 40

ⓐ 15

Sticker Name

- Oil, water, gas, steam, chemicals, air

Font: 견Gothic Font(Black),

Arrow: Red (7.5R 5/16)

Sticker Type - Left, right directions (two type)

Other

- Currently used stickers are listed in Safety Disaster Prevention System - Directly record the number of unnamed 란 - How to request for sticker: Refer to VM Guidance 69 Page

ⓑ 43

ⓒ 16

ⓓ 8

60 30

ⓐ 11

ⓑ 32

ⓒ 12

ⓓ 6

가. Pipe Flow Mark (Request Process to Safety Disaster Prevention System)

5. Sticker Standard

스 팀

99Kg/cm2

To From

Kg/cm2

B

A

ⓐ

ⓑ ⓒ

ⓓ

Sticker Name

Standard (mm) Illustration

A B Sign

Classification

Daily Inspection / Weekly

Inspection / Monthly Inspection

35 35

ⓐ 14

ⓑ 21

ⓒ 10

ⓓ 19

ⓔ 8

ⓕ 8

28 28

ⓐ 11

ⓑ 17

ⓒ 8 Remark

ⓓ 15 Basic Color

- Daily: Yellow (0.1G 5.2/6.2) - Weekly: Green (6.4Y 8.4/10.3) - Monthly: Red (7.5R 5/16)

Font & Border - Title: 견Gothic Font(Black), Writings: Gullim(Black), Border: 1m(Black)

ⓔ 6

ⓕ 6

나. Regular Inspection Sign (Request Process to EP)

5. Sticker Standard

Time

Part

A

B

ⓑ

ⓐ

ⓓ ⓒ

ⓔ

ⓕ

Name

Standard (mm) Illustration

(Arrow: Red 7.5R 5/16) A B ⓐ ⓑ ⓒ ⓓ ⓔ ⓕ ⓖ ⓗ

Rotation

120 60 15 33 9 12 45 6 4.5 1.5

80 40 10 22 6 8 30 4 3 1

60 30 7.5

17 4.5 6 23 3 2 0.7

40 20 5 11 3 4 15 2 1.5 0.5

Sticker Name Standard(mm)

Illustration Diameter(A) Gap

Gauge Sign Normal; Green 110 ￠

(10칸)

B 10

C 5 Gauge Sign

Warning; Yellow

60 ￠ (5칸)

B 10

Gauge Sign Trouble; Red C 5

라. Pressure, Gauge Limit Sign (Request Process to EP)

5. Sticker Standard

B

C

A

다. Rotation Direction Sign (Request Process to EP)

A

B

ⓐ

ⓒ

ⓑ

ⓓ ⓔ ⓕ ⓖ ⓗ

VM guidance

Visual Management

눈으로 보는 관리 사무실, 공장, 현장의 가시화(可視化)

포항제철소

Contents

Chapter 1 : VM Guidance ○ Color Management

- To manage inventory management, type of machines, type of products, oil, and documents by their colors ○ Shape Management - To manage reparation tool, material, spare part, hand tool, cleaning equipment ○ Sign Display Management - Lining, painting, quantity, 정품, inventory list, status board, fire extinguisher, label, name plate, flow direction sign, etc ○ Site Management - Facility management, production quantity, work, safety, quality, Standard Operation Procedure, electricity, ‘Choice of Quality’ Management, etc

Chapter 2 : VM Outline (Reference) ○ VM Outline

- Purpose, concept, principle and method of VM ○ VM Know-how - Representative Instrument of VM - Things invincible in VM - 5 steps to implement VM - Direction of VM development - Sequence point of VM ○ VM Management - VM Management Improvement Point - Check Sheet - Inspection Items Check Point - 10 Points and Improvement Tools ○ ‘Choice of Quality’ Certification - SOP, Diagnosis Evaluation Sheet, Diagnosis Flow, Diagnosis Application Form, Evaluation Table, Diagnosis standard, etc

VM Guidance

혁신지원그룹

Chapter 1

Item Detail

Purpose To easily differentiate an item with many type and specs by marking it with color

Target Equipment, lubricant, 철강제(재질별, 규격별), 금형 등

Method Marking with colors to allow people to easily differentiate the type of lubricant oil Mark with 10cm width color band, 15cm from the bottom of the box

Illustration &

Standard

1. Color Management

가. Type of Oil Management

Type of Oil How to use oil sticker

Brown Green Yellow Red

Decelerator #150

Hydraulic Oil #32

Pump Oil #46

Grease

* Oil adding: Blue, Oil change: Red

* 최근 교체일 (가능한 1일, 15일 조정)

* Replace the sticker if it can’t be identified

* A Type Sticker is given within one month 주기가 1개월 이내인 개소에만 사용(월1~2회)

* B형 스티커는 주기가 1개월 이상인 개소에 사용(단위: 0개월)

* Check sign must be given after grease injection

* Grease sticker should be replaced every year (and check sheet both)

(Example of Color Management)

1. Color Management

Gas Pipe Color Marking 약품 정량관리

Oil Storage Panel Status Display

Item Detail

Purpose Allowing anyone to easily check and measure whether the gauge guide line is in or out of the normal value range through color marking.

Target Pressure gauge, vacuum gauge, thermometer, ampere meter, volt meter, oil level gauge, operation status indicator

Method

Mark the normal value area with green color. Lower limit range marked with yellow color and higher limit range marked with red color. Tools used are tape, film, and paint marker (for indoor use only) Gauge that can be opened should be marked on the inside part of the glass.

Illustration & Standard

나. Gauge Limit Usage Range Mark

Gauge mark(Width: 5mm)

1. Color Management

Paint Marker (Indoor use only)

How to request: Employee Place

Supply Request ManagementSupply Purchase Request

(Attention: Color loss may appear after long time exposed in the outdoor area

Operation area: Green Warning area: yellow Trouble area: red (Able to operate, difficult to control) Trouble area: Red (Unable to operate) * Normal limit of air pressure gauge, steam pressure gauge, vacuum gauge etc need to be maintained

Kg/cm2

1). Gauge Marking Method

Attached on the outside border Attached on the glass Attached on the inside

2). Temperature Marking Method

600°C

최저

900°C

최고

900°C 최고

600°C 최저

상한 하한

하한 상한

LOW

ZERO SPAN

NI

항목 Range

전분입액 40~45

Response 38~40

Naturalization 38~40

* Operation range on the upper right side of the temperature

1. Color Management

* Mark the range limit with 5mm color sheet on the right side of the temperature surface * Green: Normal value * Yellow: Out of normal value

3 0

2 0

1 0

0

4 0

Upper limit

Lower Limit

2 0

0

4 0

3 0

1 0

Normal

3). pH Meter, Flow Meter Marking Method

표기 눈금 상단에 관리범위 표기(4mm 실선)

Analog Type

Area Flow Meter

1. Color Management

* Danger: Yellow

* Normal : Blue

* Overload: Red * Upper limit:Red

* 적정수위: 녹색 * Overload: Red

• Upper limit

* Lower limit

4). Voltmeter, Ampere meter Limit Tolerance Marking

(Example of Gauge Marking)

Pressure Gauge

Level Gauge Temperature

Cooler

1. Color Management

Amperemeter

Flow meter

가. Office Utilities Management

Item Details

Purpose To manage the utilities by carving the shape of the object and keeping them at the carved places.

Target Office utilities (Writing tools/Other), Table drawer

Method

The board should follow the object’s shape or attach a stopper Arrange the utilities to make it easier to grab Use floor material for items that can be arranged on the floor (Such as rubber board, hard sponge, Styrofoam, EVAfoam, etc) Fixed it by carving the shape on mat, hard sponge, or iron board

Illustration &

Standard

* EVAfoam thickness: 5mm

Shape arrangement of common office supplies

• Writing tools, name card, personal office needs should be arranged by their shape

• Pending documents and personal documents

2. Shape Management

(Example of Office Utilities Management)

2. Shape Management

Common Office Utilities

나. Reparation Tools Management

Item Details

Purpose To manage the reparation tools by carving the shape of the object and keeping them at the carved places.

Target All kind of reparation tools in the plant

Method

Carve or mark the shape of the tools on the keeping spot Arrange the utilities to make it easier to grab Use floor material for items that can be arranged on the floor (Such as rubber board, hard sponge, Styrofoam, EVAfoam, etc)

Illustration &

Standard

2. Shape Management

* Installation by carving the shape on the steel plate using laser (suitable for heavy tools)

* Carving the shape of the tools on floor material such as mat or hard sponge

Wooden Material Hard Sponge & Color Mat Material

Steel Material

* Use paint for background, mark the shadow with color sheet, and stick the name

(Example of Reparation Tools Management)

2. Shape Management

Tools inside the drawer Fixed tools Movable tools

다. Tools Management

Item Details

Purpose To manage the tools by carving the shape of the object and keeping them at their carved places.

Target All kind of tools in the plant

Method

Carve or mark the shape of the tools on the keeping spot (arrange the utilities to make it easier to grab) Use floor material for items that can be arranged on the floor (Rubber board, hard sponge, color mat, 흡착재, etc.) Attach the list of the tools, always keep user name plate on the right side of the toolbox and write the destination of the user Frequently used tools should be stored separately, classified by its set, and it should be easy to moved ( e.g: wiper change tools, etc) The toolbox should consider the tools size and length and the usage frequency

Illustration & Standard

• Outdoor Toolbox

Minimized Outdoor

Equipment Toolbox

• Moving Toolbox • Indoor Toolbox

Equipment Toolbox for Arranging Knife Minimized Indoor

Equipment Toolbox

1200

300 600

300

850

800

Rack

1650

900

1100

500

2. Shape Management

(Example of Tools Management)

2. Shape Management

Hook Type Toolbox

Open Type Toolbox Moving Toolbox

Fixed Type Toolbox

Item Details

Purpose To easily manage the spare part / material by carving the shape of the object on the toolbox and keeping it on each of their carved places.

Target Each facility’s spare part and material (불급품 included)

Method Carve the shape of the tools on the keeping spot Use floor material for items that can be arranged on the floor (Rubber board, hard sponge, color mat, 흡착재, etc.) Attach the material list and classified it by their usage frequency, function, machine, and 용도별

Illustration & Standard

라. Spare Part / Material Management

초자기구 형적정돈 불급자재 형적정돈 소모성 자재류 형적정돈

2. Shape Management

(Example of Spare Part / Material Management)

초자기구 정밀 부품류 Type of Bolt

2. Shape Management

Spare Parts 소형 기계부품 각종 센스류

Item Details

Purpose To facilitate everyone in searching and using the cleaning tools

Target Each cleaning tools and equipment

Method Make the hanger type keeper for cleaning tools, mark the spot and superintendent’s name for each tool and always attach the name of the tools

Illustration & Standard

마. Cleaning Tools Management

Cleaning Tools Hanger / Box

Cleaning Tools Hanger

Mop

Managing Dept.

Innovation Support Group

P.I.C Choi Hyung

Shin

• Blue background, white font : Width100mm × Length30mm

• Green background, white font : Width 400mm × Length 80mm (Edge: 30mm)

• White backround, black font : Width100mm × Length60mm

2. Shape Management

* Store the tools that can’t be hanged inside a bucket shaped keeper and attach the tools’ name and quantity in a place easy to see

(Example of Cleaning Tools Management)

2. Shape Management

Cleaning Tools Storage

3. Sign Display Management

Item Details

Purpose To clearly draw the dividing line in passageways in order to prevent accident and clearly mark the direction

Target Passage border line, parking line, work passage line, entrance sign, direction sign, etc

Method Draw basic line using ink line then using roller brush do the first painting. Then, do the second painting using brush. To make the line clear and straight, cover the outer part of the targeted area with plastic tape before painting, and after the paint dries the tape may be taken away.

Standard

1 0 0 mm

1 0 0 mm 1000 mm

100 mm

1 0 0 mm 1 0 0 mm

3 0 0 mm 5 0 mm

5 m

3 0 0 mm

Work Area

100mm

3 0 0 mm

1 5 0 mm

2 0 0 mm

50mm

1 5 0 mm

7 5 mm

1 0 0 mm

가. Floor Line Sign Display

Work Area

Work Area Work Area

(Example of Floor Line Sign Display)

Electrical Room Passageway

3. Sign Display Management

Lab Passageway 유압실 통로선 Plant Passageway

Item Details

Purpose To mark the original position of all movable objects and to make organized arrangement as a habit

Target Isolated Inaccessible Area for Safety: Tools Storage, Cleaning Tools Storage

Fixed Area: Cart, Wheeled storage, etc

Method

Isolated Inaccessible Area for Safety - Color : Yellow - Color : Yellow - Mark with □ shape - And mark corners with ㄱ,ㄴ shape

Fixed Area

Illustration and Standard

나. Half Fixed Utilities and Moveable Utilities Line Marking

3. Sign Display Management

50mm

50mm

(Example of Dividing Line Marking)

Moveable Object Electrical Panel Passageway Line

3. Sign Display Management

Lab Passageway Line Door Access Sign Work Room Passageway Line

Site Passageway

Item Details

Purpose Setting up a fixed place for tools to make it easier to use and prevent loss caused by searching the tools

Target Work table, mechanical device, gauge, instrument, material storage, trash bin, raw material, product pallet, etc.

Method To attain a spacious work place and to mark the original position of fixed work table

Standard

다. Object’s Original Position Marking

PALLET

Work table and the line’s size might be different according to the size of

the object. Usually:50mm

Might be different according to the size of objects above the work table. Usually:10mm

Flammable Nonflammable

50mm Width Color band

50mm width area marking

Blue background, white font

Can, etc

Cart

Distance between cart and line : 50mm

50 mm

50mm

Cart Welding Machine

Width 50mm line around and fill the inner part with reddish brown color

3. Sign Display Management

(Example of Original Position Marking)

청소차 Storage Moveable Toolbox

3. Sign Display Management

Instruments

Lift Storage

Item Details

Purpose Visible management to attain safety for all workers (Door’s open-close range, 적재금지)

Target Hinged door, sliding door

Method Hinged door: draw yellow line (according to door’s open-close direction) Sliding door: draw tiger line and dotted line (put door’s open-close direction sign)

Illustration & Standard

Hinged door (blue background, white font)

라. Entrance Door Radius Marking

Open Close 28mm

55mm 25mm

20mm

Sliding door Open: White background, blue font Close: Blue background, white font

50mm

50mm

50mm 45 o

50mm 50mm

50mm

3. Sign Display Management

P U L L

P U S H

105mm

40mm

(Example of Entrance Door Radius Marking)

Two side door

3. Sign Display Management

Work Room

One side door(1800) One side door(900)

Plant Entrance Door

Item Details

Purpose To make a convenient walking space while preventing accident in stairs or facility’s floor

Target Stair and facility’s working space’s floor or wall

Method Allowing simple identification of process place through direction marking using yellow colored acrylic, paint, or tape

Illustration & Standard

마. Passageway Direction Marking

Direction marking

Slogan, Team’s Target, etc (To write process and CAPA, facilities etc is prohibited) * Font: Black, 견Gothic Font * Background: Yellow Official name or destination place name

10cm 20cm

20cm

20cm

Stairs direction marking

3. Sign Display Management

(Example of Passageway Direction Marking)

Marking Direction Sign board Caution Sign

3. Sign Display Management

Location Sign

Item Details

Purpose To prevent accident by raising the workers’ awareness of the dangerous area

Target Elevator in dangerous area, hoist lower part, in front of 내외부 확인 곤란한 출입문 앞 등

Method Tiger mark: 50mm width of black and yellow line Caution mark: Black frame(30mm), yellow background black font Safety cover(방호울): Body(Yellow), Net(Black), Rotation direction mark (Red background, white font)

Illustration & Standard

바. Danger and Safety Sign

45 o

주 의

Danger sign (Tiger mark) Caution Sign Safety Cover

3. Sign Display Management

Sign Confirmation Place

표지판 종류 모형

문자표지판

GAS/Hazardous Material Warning Sign

계몽표시

Guide sign

(위험 안전표시 예시)

3. Sign Display Management

설비받침대 계단/설비받침대

Column/머리조심 돌출함 장애물

접근금지

Item Details

Purpose Allowing people to know about the operation status and prevent accident by attaching rotation direction mark on each operating motors.

Target Each motor, rotor, etc

Method Marking using sticker, coating, acrylic, tape, painting The sign should be attached at easily visible places with the same direction as the rotation When attaching the rotation details etc needs to be recorded.

Illustration & Standard

사. Rotation Direction Marking

3. Sign Display Management

• Front side • Upper side

Sign position

A

B

ⓐ

ⓒ

ⓑ

ⓓ ⓔ ⓕ ⓖ ⓗ

Name

Standard(mm)

A B ⓐ ⓑ ⓒ ⓓ ⓔ ⓕ ⓖ ⓗ

RO

T

O

R

120

60 15 33 9 12 45 6 4.5

1.5

80 40 10 22 6 8 30 4 3 1

60 30 7.5 17 4.5 6 23 3 2 0.7

40 20 5 11 3 4 15 2 1.5

0.5

Standard of the rotation marking sticker

(Example of Rotation Direction Marking)

3. Sign Display Management

Motor

체가름 설비/ Jaw crusher Other Rotating Machine

Item Details

Purpose To allow facility performance identification through attached open-close marking on each valve. Allowing any worker to check the operation status through additional attachment of usage or related operation description

Target Valve from each line and utility related valve, damper

Method

Valve handle shall be painted in colors such as yellow, blue, etc depends on the usage and the shaft area shall be colored in red. The lower part of the damper control lever shall be marked with directions arrow classified by colors Mark using tape, film, painting, 포맥스 etc. On places hard to attach, the hanger type sign/mark should be used.

Illustration & Standard

자. Valve Identification Marking

Damper

* Handle color Yellow: Gas, White: Air Blue: Water, Green: Chemical * 5mm red line valve open mark on the shaft

Ball Valve

* Product insertion direction depends on the operating direction of the damper control lever (B direction – open, B direction – product insertion)

* Operating direction mark (1st reservoir / 2nd reservoir 저장소)

CLOSE

When facility’s

operating CLOSE

Open

When facility’s operating

OPEN A Open BClose

A B

3. Sign Display Management

Open Close

Label

Normally closed

Valve current status

Valve mark Adjusting handle

Air

Open-close control valve

Diameter:5￠

Rotating open -close valve

* The valve name should

be stated clearly

* Adjusting the handle will change the status

(Example of Valve Marking)

Pressure gauge Other Valve Damper

3. Sign Display Management

Cock valve Label type Handle valve

Item Details

Purpose To allow anyone to identify the utilities such as equipment, tank, etc

Target Each motor and rotor, designated parts of equipment설비 체결 부위

Method Mark the joint part by drawing (3~4mm) red line on D bolt and nut Attach sparkling tape on air vane Marking to make easier safety cover installation

Illustration & Standard

차. Facility Management Marking

Identifying motor’s wind flow

3. Sign Display Management

Joint location marking

※ 설비 체결 부위 bolt, nut, etc should be marked with 3~4mm red line

Line width: 3~4mm red line

2~3 산

Pinwheel

*Rotating pinwheel

Control panel

Fan

Spot adjusting

Fan Cover Coupling cover

Thermo label

(Example of Facility Management Marking)

3. Sign Display Management

Marking joint spot

Motor pinwheel

기관차 선로 차입위치표시

Item Details

Purpose To easily identify fire extinguisher indoor or in the plant and fire hydrant and easily doing checking inspection and management

Target Plant and indoor fire extinguisher, outdoor fire hydrant

Method Marking after coating with pressed styrofoam, acrylic, tape, or paint. Placement height should be 1700mm from the ground to make it easily visible for anyone to see

Illustration & Standard

카. Fire extinguisher, fire hydrant sign

3. Sign Display Management

1.7m from the ground

Fire extinguisher

3 0 0 ㎜

Hydrant

3 0 0 ㎜

Magnetically attached

Fire hydrant

※ If the placement could not reach 1.7m height, it should be moved to another place that fit the proper height

(Example of Fire Extinguisher Marking)

3. Sign Display Management

소화전 앞 적재금지 Hydrant hose arrangement

Nude Hydrant

Item Details

Purpose To increase the effectiveness of working through easier documents searching and returning

Target SOP, documents, manuals, papers, etc.

Method Marking the document’s original position on the side part to make it easier to return the document Attach each document’s name or document list on the base of the shelf or use numbers to simplify the searching

Illustration & Standard

타. Document Marking

3. Sign Display Management

SOP (Seagull shape) Manual (Diagonal shape)

(Example of Document Management)

Fade-out type Numbering type Seagull type

3. Sign Display Management

Item Details

Purpose To create independent image on each department’s name plate and the organization

Target Entrance door of each department, toolbox, material storage room, bookshelf, notice board, computer room, laboratory, ‘authorized personnel only’ area

Method Dept. annotation should be located on the left/right side of the entrance door with 1.7m height to make it easily located, and related departments annotation should be attached on the ceiling Title of notice board, storage room, book shelf

Illustration & Standard

파. Name plate sign

Sign board (Acrylic)

혁신지원그룹

Cleaning tools

storage

No entry (Acryl/포멕스)

Main title (Stainless)

Sub-title (Foam board/포멕스)

* Size 32cmX13cm

* Navy blue size 32cmX2cm

* Size 25cmX6cm

* Black font

* Size 30cmX10cm

* Black font (Red diagonal line)

* Size 20cmX5cm

* Black font (Spring grass color with filling effect)

Emergency number (Acryl)

3. Sign Display Management

Emergency Phone Number

PIC Day Mainte

nance

Nigh

t Operat

ional

Holidays

운전실

Authorized Personnel Only

* Acryl, magnet type, 320X210X5mm, white background, black font

* Small materials or general material should use p-touch and be attached after printed

(Example of Name Plate Sign)

Sign board Facility name (STS) Facility’s name(Acrylic)

3. Sign Display Management

Emergency Phone Number

Sign board (Acrylic)

Sign board

Item Details

Purpose To easily identify the stored spare part or material in a facility

Target Products or spare part, material, sub material, equipment and gauge

Method Sticker size should be made according to the spare part’s size My Machine: Photo printed in color and should be attached on the facility using rubber magnet after coating Office appliances: Contents of the appliances should be printed and coated before attached.

Illustration & Standard

하. Marking Label

Material Label (White 50mm×20mm)

Name

Quantity

Stocked Date

Max/Min

Use date PIC

3. Sign Display Management

My Machine Label (Blue sky 150mmX100mm)

* If the machine cover is not made from steel then thin iron plate should be attached 컴 퓨 터

관리번호 (포) 혁신지원그룹- 001

용 도 사무 업무용

관리자 홍길동(혁신지원그룹)

Office Appliances Label (Blue sku 60mm×40mm)

후판 절단용 User

06-02-001 Code No.

25t 샤링머신 Machine Name

1) Label for Quantity Management

Requirement card (290mm×200mm)

3. Sign Display Management

To eliminate overstocked goods by managing the quantity of the goods All goods that already been piled up in the storage and need to be managed (material storage and spare parts)

1 5 ㎜ * Upper line: Red line marking

* Lower line : Blue line marking

* Use 50mm width tape for large shelf, and always make it easily visible

Goods name Quantity

Width of the shelf

Large:200mm Medium:100mm Small: 60mm

Large:140mm Medium: 70mm Small: 40mm

Number (Address) Label (70mmX50mm)

* Alphabet (30mmX30mm)

* Hangeul (40mmX40mm)

* Background: Dark blue, light blue

* Background: Light blue, light red

3. Sign Display Management

1 2 3 4 5 6 7 8

※ If the storage is not transparent, put a picture to allow people know about the content and a PIC for the item should be selected

2) Numbering and Location Management

To easily manage and search for the material or spare part on the storage

Material storage, spare part storage (amount, quantity, type of good, numbering label)

Sign should be attached on the center part of the storage or display cabinet

Use rectangular shaped styrofoam and finish with coating the surface

(Example of Managing Label)

3. Sign Display Management

Material Label Spare Part Label

Numbering Location

Facility Management

Item Details

Purpose To share information regarding QSS activity through VM and helping the improvement activity 단순히 보여주기 위한 전시성, 과시성 게시 배제 Eliminating sense to simply displaying things and unimportant notice

Target Factory sub-center’s front hall, QSS Enforce Team Office, Team’s Workroom

Method Place: Factory sub-center’s front hall, QSS Enforce Team Office, Team’s Workroom Executing each activities according to the standard guide on the activity board All contents should not be printed in color

Illustration & Standard

가. Managing Activity Board

Activity List Standard Activity Board in Team Work Room

4. Site Management

• 부 서브센타 현황판 부착이 필요한 부는 공장서브센타 기준으로 부착 • 기 활용중인 현황판은 게시물의 명칭을 표준가이드 명칭으로 변경하여 사용 • 반 작업진행실은 특성을 고려 반단위 또는 동일업무 단위로 통합하거나주임단위로 부착

(Example of Activity Board)

My Machine Activity Factory Status Board

QSS Activity Board

Task Execution Board

4. Site Management

Item Details

Purpose To reduce time needed for motor inspection and to prevent accident when checking the operation status of the machine

Target Motor BOX, Electricity PANEL

Method No related procedure method. Post-management standards after reforming should be made and attached

Illustration & Standard

나. Facility Management (Inspection Glass)

4. Site Management

Inspection glass Fuel inspection

Steel

Using one touch bolt

Using transparent acrylic

Transparent hose

Conventional oil gauge

Reformed oil gauge

티

Single valve (The length should be adjusted to reach the drainage spot)

transparent acrylic

Net access hole

(Example of Inspection Glass)

Fire extinguisher pipe Sense Relay Motor

Hydrolic/Pneumatic Rotation state Power Supply Box

4. Site Management

Flowmeter

다. Facility Management (Operation Rate, Operation Standard)

Item Details

Purpose To identify facility maintenance and inspection place with one look and improving facility’s operation ratio.

Target Work process and main facility

Method Managing attachment on main facilities and activity board on producing factories

Illustration & Standard

Places for maintenance inspection should be listed, the list should be attached beside the related machine to make the maintenance inspection spot can be identified easily. Make work procedure for each maintenance inspection item related to the list. New occurred trouble etc should be added frequently to the maintenance inspection list and the contents should be planned carefully.

4. Site Management

보전, 점검일람표

‘오일탱크’

수분제거

작동유유량계

에어필터 교환

작동시 이음

급유(Grease) 윤활유 유량계

볼트풀어짐

리미트 SW

보전, 점검일람표

‘오일탱크’

수분제거

작동유유량계

에어필터 교환

작동시 이음

급유(Grease) 윤활유 유량계

볼트풀어짐

리미트 SW

50

60

70

80

90

100

%

Apr May Jun Jul Aug

Target

Line

* If data such as valid operation rate, operation rate time, operation rate speed can be obtained, we can make a more clearer management of the operation

(Example of Guideline Management)

Inspection Sheet Using Instructions Guide Line

Work Flow Exterior Specification

4. Site Management

Layout

라. Production Quantity Management

Item Details

Purpose To know whether there is “delay” and “과진행”or not, why the production didn’t work as planned, what’s the cause, and to find the clue to help problem analysis and problem solving and solving the problem.

Target Half-product and final product

Method By managing the QSS activity part on activity board, per-team

Illustration & Standard

1 2 3 4 5 6 7 ~ 31

Plan line

Plan line

Factory Dept Line Yr Month

Graph shows the progress of production through comparison between monthly production plan and the actual status. Graph shows “과 진행” if the actual line located above planning line , if it’s located below planning line it shows “delay”, plan achievement 계획의 달성 정도를 관리할 수 있다.

4. Site Management

Pro

d.q

ty

(Example of Current Stats Management)

Production Quantity Management Daily Settlement (per-team)

4. Site Management

Injury Record Board

Item Details

Purpose To allow immediate control of defects or trouble throughout the process; to alert the supervisor.

Target Work process and facility

Method Attachment on work line and main facilities

Illustration & Standard

마. Work Control (Andon)

2 3 4 5

6 7 8 9 10

1

Trouble Alarm Signal Light

Oh! There’s

something happened

inside the factory . . .

삐~~ 삐~~

• If trouble occurred, worker can push the beeper button in front of their hand, allowing supervisor to come immediately and take emergency action. Or to stop the line works according to the rule. • To make it more effective, the workers should be ordered to push the beeper button even for minor cases, and the main point is to make it as a habit.

4. Site Management

(Example of Andon Installation)

Managing Operation

Managing process line

Alarm

Line/Warning Light, etc

4. Site Management

Item Details

Purpose To prevent defect recurrence by placing the product in an easily visible place and to quickly divide the fine and defected products through visual evaluation

Target Half product and finished product

Method Controlling on the production site

Illustration & Standard

바. Quality Control

•There’s a case where transportation method with similar function as defect product yard’s is used but if the repetition rate is too high or the damage is too big, data comparison needs to be done and the product shall be displayed.

•Facilitate the improvement or to prevent recurrent through increasing workers knowledge regarding product quality to make the method more effective.

4. Site Management

Color-classified Products Limit Sample (E.g.)

(한도) (방법) (한도)

Color Classification

• The most effective way to examine defect is to make limitation sample for comparison because there’s very little case of numeric data problem when dividing between fine products and defected products, but when examining defects by color, scar, stain, surface and other appearance standards, it is proven hard to obtain one objective standard.

• This method is also used in the inspection dept. but to execute a simple and valid inspection inside the facility is also important.

• Make plenty of limitation sample and also analyze the process, place, and method use in the related place to make the method more effective.

Install display for defected products

1 2 3 4 5

(Example of Quality Control)

Raw Material Sample Display

Defect Sample Display

4. Site Management

사. Electrical Management (Switch, Socket, Wire)

Item Details

Purpose To increase electrical awareness and accident prevention through naming of each switch and attaching load name, usage purpose, and the PIC. To increase the usability of socket through visual control by naming the socket and attaching usage purpose.

Target Transformer room, power receiver, electrical DCS Room and other electrical switch.

All socket and wire inside the plant.

Method Attaching board containing information such as panel usage, load, and circuit’s diagram. 콘센트와 콘센트 접속손을 1:1 정보표시를 함 Assign managing PIC for control and management should be based on power saving and safety.

Illustration & Standard

Managing PIC sign and load. Circuit’s diagram placed

beside the switch or beside the entrance door to allow

people to see and make sure first

4. Site Management

Wire knotting point

(Example of Electrical Management)

Socket 출처 Wire Sign

Electrical Panel Switches

Switch

4. Site Management

Item Details

Purpose 5S, My Machine that become role model for other; a facility or area nominated for company’s intern benchmarking

Target Office room with material, tool, or document, and work area with installed facility

Each level of buildings, team, supervisor’s work area, or facility

Method

Judgment process: Request evaluation certification (only the one with evaluation average score above 85)

Judge member: Plant Manager(PO), QSS-Master, Safety(Facility)Supervisor, Consultant (5 persons)

Certifier: General Manager (Winner)

Illustration & Standard

Numbering method

Certification Board Size

아. ‘Choice of Quality’ Management (5S, My Machine)

4. Site Management

Classification

Numbering

Method

Certifier Managing PIC

명품

Dept-Plant-Certification Number

General Manager (Winner) Operational

Support Team ○○-○○-4 digits SMP-1SMP-0001

Classification Size(mm) Thickness(mm)

Stainless Steel Board 180×120 1

Acryl Board 180×120 3

* Stainless Board or flag, depends on the plant’s condition

Inserted phrase on the certification board 여러분들이 한마음 한뜻으로 만들어낸 상기 설비를 QSS 명품으로 인증 합니다 “This facility made from your one heart and one purpose is acknowledged as QSS Choice of Quality”

Certification plate should be placed on the facility or the entrance door

(Example of Managing ‘Choice of Quality’ Certification Board Attachment)

Material Warehouse Air Compressor Room

4. Site Management

Sampling Plant

VM Introduction / Reference Material

혁신지원그룹

Chapter 2

가. Purpose of VM

Difficult to check the facility’s status Difficult to check UT Quality Operation based on feeling

Instantly alerted Identifiable Predictable

Increasing production efficiency and reducing cost price ① Stock cut-down and reducing lead time ② Increasing operational ratio, work efficiency and reducing man hour ③ Reducing progress delay and delivery delay ④ Reducing defects ⑤ Reducing cost price Increase speed of office and plant works

To simplify management works

Direct Purpose

Increase standard of management 자율 신경이 깔린 조직 체질의 확립 Establish a bright and dynamic business climate

To create an effective and fun working atmosphere

Eventual Purpose VM의 추진

1. VM Introduction

Make method from environment around

Alerting anyone about normal/trouble state

Supervisor should take immediate action to handle trouble

Trouble Occurs

Finding Trouble

Immediate Action

(Find the cause)

Improve- ment

Method

人

나. Concept of VM

1. VM Introduction

“정상과 이상을 누구라도 한눈에 알아 볼 수 있도록 하는 것”

A preventive management to

accurately, easily, and suitably judge

situation in the constantly changing

production site and maintaining normal

state with immediate action when

trouble occurs.

VM as a tool Unseen

Hard to see.

Make it visible. Can be seen.

Fastest Action

Improvement

To let anyone know easily

Items Contents

Control Limit Marking ㅇ Control limit between normal and not normal should be stated clearly

ㅇ Limitation should be decided quantitatively

ㅇ Should allow trouble identification from afar

Transparency ㅇ Make inner parts visible to easily identify any abnormality

ㅇ Take off any lids in case it can’t be seen

ㅇ Change the place in case it can’t be seen

Visualization ㅇ Use sign or mark

ㅇ Do Color Management

ㅇ Can be seen from afar ㅇ Marking objects for maintenance ㅇ Allowing anyone to identify good or bad status ㅇ Allowing anyone to use equipment conveniently ㅇ Allowing anyone to maintain equipment ㅇ If the (above mentioned) tools are used, the conveniently work atmosphere will be brighter and clearer

Point of VM Tools

다. Rules of VM

1. VM Introduction

Working based on Supervisor’s order

Management to make people work based on situation

Instead of concealing the trouble

Management to solve trouble based on the current state of work

Monopoly of information by supervisor

Lead whole workers to participate for information sharing

Site where

management, supervisor

can quickly take action

<Site that can easily be identified by one look>

• Trouble points

• Normal/abnormal status

• Loss

현장에서 자율신경을 갖게 만드는 것

Allowing anyone to see the normal or troubled status

현장에서 자율신경을 갖게 하는 것

Management to allow anyone to examine what is the trouble point

라. VM Method

1. VM Introduction

가. Representative Tools

Sign Management

Site Management

Color Management

Shape Management

VM Classification

방법 작업표 Pedestrian walk line, 방법 재공수, T/Time 사람과 설비의 재공수 등 표기

Site

Management

Andon Abnormal quality, machine trouble, alert sign activated by worker in case of trouble, etc.

Production

Management

Board

계획 대 실시 진척 정도, operational status, 정지요인,지연요인 등을 알고 대책

Status

Management

Board

Accumulated production quantity Actual/plan graph, activity board, Facility management current stat board

Other Defected goods’ box, defected goods’ display, 명가Gant Chart, Pace Maker, 명품,명소

Quantity

Management Stock control by color classification

Color

Management Managing type

of equipment

Color unification for machine, product type. Color classification for oil and documents

Equipment

Management Manage equipment to be returned to its original place after being used

Shape

Management Cleaning Tools

Management Manage cleaning tools to be returned to its original place after being used

Sign

Management

Area line Safety passage, work area line, 치장 구획선, door’s open-close sign

Sign board Signboard, Marking for stock’s max/min limitation, 불량 치장선

적정표시 Level gauge, valve, thermometer, Indicator, limitation and 적정표시

Information Sign

Man hour, production, signs, outsourcing, temporary sign between each process, work order, delivery order, finished product 인수 (handover) information

Marking Facility, etc

Marking rotation direction of motor or machine to show its’ operational stats

Fire

Extinguisher

Sign

Fire extinguisher & hydrant location, Usage method, maintenance method, Inspection list

2. VM Know-how

나. Things cannot be seen through naked eyes

Oversized Object Object that is

too small Formless Object Fast Object

Currently Nonexistent

Object

Unreachable Object

Dark Object (With no lighting)

Complicated Object

Covered Object

Make e

very

thin

g v

isib

le

To m

ake it e

asie

r to

undre

sta

nd

2. VM Know-how

다. 5 Steps of VM Implementation

2. VM Know-how

Step1. Make a clear purpose

Step2. Decide the items to manage

Step3. Design the format for management

tools

Step4. Decide the spot to install the management tools

Step5. Make usage rules and always remind the user

Attaching mark/signs to make every objects easily identified.

Size of the object’s name should be made

according to the object’s size Use colors efficiently, marking classified by the

size and colors Making a system that allows everyone to see

without having assistance from other person

Fast Action

Seen at

one glance

Not visible

Hard to see

Improve- ment

1 STEP

Creating site that can be identified through

seeing

1.Executing general cleaning

2. Executing 적찰 strategy

3. Classifying floor area (passageway,

object placing spot)

4. Facility Status Sign.

( Operating , 기종 replacement, Out of

order sign)

5. Process Line Name and PIC Sign

5 S

2 STEP

Visual Management

1. Method and Work Manual

2. Set up process receiving method based on the sign(for all company’s products)

3. Marking pallet and places for storage

4. Set up mark for production target and actual, process rate, production improvement mapping

5. Install board for managing improvement progress.

Production Management Board, Standard Works

라. VM Development Orientation

Without improvement the system made is unusable.

1. Build a consistent production line.

2. Set up and marking Cycle Time.

3. Build a synchronized production

system.

3 STEP

Andon

2. VM Know-how

<Definition of VM> ‘A managing system that make abnormalities visible by one

look and enabling fast improvement.

Factory Make site problems, abnormalities and loss visible

Share information • Work visualization, standard • Work regularization, simplification

VM

1

Office 2

Step-0 Step-1 Step-2 Step-3 Step-4 Step-5

I

T

E

M

Cleaning Area Floor, pipe painting Classified by usage

선긋기 간판

붙이기 재고

3정표시

.Cleaning the space -Ceiling -Wall -Floor

.Plant

.Office

.Product Warehouse .Temporary Warehouse

(Space) .Work Area Color .Passageway Color .Staff Lounge Color .Warehouse Color (Pipe) .Color depends on the contents .Facility Painting: 자주 보전 3스템이후

.Area Line

.Passage Line

.Door Open-Close Line

.Loading point line -Stock Product Defect Product -Work Area 재떨이 .Entrance Line

.Plant Sign

.Line Sign

.Plant Sign

.Machine Sign

.Spare Parts Storage Sign .Defect Product Storage Sign .ROOM Sign

-Marking Location -번지표시 .정품 -선반품목표시 .정량 -Marking max qty. -주문점 표시 -Marking min qty.

P

O

I

N

T

1.Cleaning done from top to below 2.Don’t brush or blow of the dust 3.Clean/wipe with vacuum cleaner or cloth 4.Everyone should participate

1.기둥을 이용 번지로 나눈다 2.횡(가로)방향 BLOCK화 종(세로)방향 주소표시 3.The sign should be big and clear

1.Choose colors that suitable for the usage of the room. Work Area: Colors that are comfortable for working Lounge: Calming color 2.Green for passageway 3.There should be no bump on the floor 4.Pipe should be colored according to regulation 5.Marking pipe flow

1.가급적 직선 으로 긋는다 2.앞에서 보기 쉽게 한다 3.Reduce 각진 part to make mobilization more easier 4.모퉁이는 직각을 피한다 5.Each line differentiated by the width (thickness)

1.The sign should be big and clear 2. Color unity based on process

1.Marking where what and how to allow other to know 2.Marking item position should be moveable 3. To allow amount identification by one look. 4.Not placing things outside the rack.

2. VM Know-how

마. VM Sequence Point

3. VM Management

가. VM Management Improvement Point

①Creating manual ②Seeking for and showing abnormal condition ③Prepare evaluation standard, plot everything numerically ④Creating the model ⑤Improving visible tools and system ⑥Systematically doing all activities ⑦Encourage practical use

①Obeying method and manual ②Evaluate activities regularly ③Continue making improvements ④Have a purpose and improving perseveringly ⑤Introduce new technology and information ⑥Executing systemization, theorizing and transferring, settlement ⑦Executing major re-inspection depends on the situation

Visual Management

철저한 7가지의 POINT

7 POINT of Management Improvement

나. Check Sheet

Classification No. Check Item Good.Bad (O,×)

불합리한 내용 Irrational Contents

Marking Place

1 2 3 4 5 6

Marking storage spot for equipment • 금형 • slide cart Marking storage spot for spare part • stock goods • finished products Marking storage spot for defected goods • on hold goods Marking storage spot for empty box • lot box Marking for assembly line no. and machine no. Marking for the assembly line machine PIC

Placing Arrangement

7 8 9 10 11

Equipment • 금형 • slide cart placed properly Spare part • stock goods • finished products placed properly Defected goods • on hold goods placed properly Empty box • lot box placed properly Unnecessary goods • 불급품이 방치되어 있지는 않은가?

Posting Work Standards

12 13 14 15 16

Made and post work standard for assembly line worker Made and post work standard for operator Made and post work standard for 준비교체 worker Made and post work standard for 피킹 배당 worker Made and post work standard for inspector

Marking Production

Status

17 18 19 20 21

Marking assembly line •machine operational status Marking reason and time for line stop • out of order machine Marking time and PIC for handling defected product Marking the sequence of order production Marking production progress status

현장관리지표게시

22 23 24 25

Post production qty. plan and actual progress Post target and actual progress for line efficiency•machine operational ratio Post target and actual progress for defect ratio Post target and actual progress for 준비교체 time

Check Date

Year Month Date Drafter Check Item Score Inspection & Approver

3. VM Management

다. Inspection Item Check Point

Item Check Point Visual Management Tools

Managing Process & Delivery

•Steelworks Schedule Planning, Load Schedule, Message Board •Progress Status(delay, preceding status and the cause/countermeasure action) etc.

Production Management Board, Schedule Management Board, Message Board, Work Process Management Chart, 전광진도표시판

Quality Management

•Defect occurrence (number of cases, cause, countermeasure) •Inspection standard and result for whole process •Defect handling/disposal regulation, defect handling regulation notice board, etc.

Defect graph, defect mark, storage for defect products,

불량품전표, inspection order, inspection check list.

Work Management

•Standard work, work standards, standard time •Work trouble, trouble situation •Condition of worker’s placement, commuting, and health •다능공화의 추진상황 스킬 맵, 다능공화 예정표 등

S.O.P, standard work list

Operational Status Board, Operational Sign, etc.

Trouble management board, worker placement board, commuting time table, member board

Product Management

•Stock’s location, record, use date, etc. •Total stock (excess, normal, shortage) •Unusable/defected products

Storage location/mark (product’s name, use date, process sign)

Stock list, standard stock quantity (max/min, ordering point sign)

Height limit, 결품표시판, 불요품 storage, 불요품

전표, defected products’ storage, 불량품 전표 등

Facility Management

Jig / Equipment

Management

•Jig •Tools management, machine halted, trouble occurrence. (Rotation count, time, cause troubleshooting), operational status. •Regular inspection situation and regular inspection check sheet, inspection standards •Jig •Tools’ storage.

Temporary halt record, operational status, etc. out-of-order time record. Facility operational ratio, preparation time reduction graph. 선반, 번지, item, marking stock, equipment, cutting tools storage

개선목표

관리

•Production schedule achievement status, 재공품재고 감량상황 •Reducing production lead time, space cut down situation •Defect reduction, increase productivity, 공수 감축 상황

Actual value should be recorded and compared with planned value through anything visible such as graph etc for each day, month, and year.

* What items should be made visible?

3. VM Management

라.10 Points and Improvement Tools POINT Eyes Improvement Tools

1)Find easily Detect (second) Name tag, arrow sign, lamp sign, among objects with the same shape, 동-address sign,

color classification, standing sign board

2)Closer Distance(mm),angle Hanger, waist-high height

3)Grab easily Identify Shallow storage, direction, distance reduction, weight reduction

4)Useable Function Crash stopper, anticorrosive (방청)

5)As needed Adequate amount (unit) First in first out, max/min storage sign

6)Safely Safety Passageway line, 돌출부 cushion, safety passage [danger], [caution]sign

7)Move easily Approach(mm), pass through (number of winding)

Remove obstacle

8)Aesthetically Aesthetic Same-shape storage

9)In order Sorting 평행, 직각 보관

10)Easy to put Original (storage) place Reducing insertion distance,목표치수 확장

Target Field : Created Date : Improvement Purpose : Drafter :

3. VM Management

VM Inspection Item

Current Situation

And Trouble

Improvement Layout

4. ‘Choice of Quality’ Facility Certification_ SOP

Steps Related Team Appraisal Judge GM(Winner) Innovation Support

Group Remarks

Appraisal

Request

① QSS Activity

5S or My Machine activity

② Self appraisal: SV(Team Leader)

③ Appraisal Req: SV(Team Leader)

-Able to request for appraisal with score above 85 points

-Make appraisal req. form and send the appraisal table ④ Acceptance and Inspection

- QSS Master in charge of the Dept.

⑤ Create Appraisal Planning and Notify

- Planning: QSS Master

- Notify: Form a team and appraisal schedule

⑥ Appraising

- Site inspection and data inspection

* Appraisal Judge:

Plant Manager(PO), QSS-Master,

Safety(Facility)SV, Consultant

⑦ Judgment

-Average above 85 points: Certified * decimal cut off ⑧ Certification :General Manager Handover Choice Of Quality Certificate and attaching placard * QSS Master informed Innovation Support Group about the result ⑨ Appoint PIC: SV(Team Leader)

⑩ Regular Inspection and Improvement: 5S or My Machine PIC and team members

Accep-tance

Appraisal

Certify

Manage-ment and Mainte-nance

①QSS Activity

②Self Appraisal

③Appraisal Request

④Accept & Inspection

⑤Make Appraisal Planning and notify

⑦Judgment

N

⑧Certify Yes(above 85 points)

No(under 85 points)

Accepting certifi- cation result

⑨ Appoint My Machine PIC

⑩ Regular inspection & improvement

⑥Appraising

Y

Request Form for ‘Choice of Quality’ Facility Appraisal (5S) (Appraisal Sheet Score as Reference)

Affiliation SV Name

중점 추진 내용

Activity Period Self Appraisal

Date

Appraisal

Request Date

Expected Date of

Appraisal

Classification Item Score/Point

Self Appraisal

Appraisal Score

5S Activity Point

Learning Club Point

Improvement

Activity Point

Thoughts About Activity

System Point

Main Activity

Result

Number of Loss

Finding

number/person

Number of

Suggestion number/person

가. Request Form for ‘Choice of Quality’ Facility Appraisal (5S)

4. ‘Choice of Quality’ Facility Certification

나. 명품 진단표(5S) Affiliation

Appraisal Date

Activity Name Appraiser

Classification

Appraisal Item Appraisal Point Scored Result S

(100%) A

(80%) B

(60%) C

(40%) D

(20%)

5S Activity (60)

Office Environment

Are the documents neatly arranged? 10 10 8 6 4 2

Material Warehouse

Are the materials already classified to make more easier searching?

10 10 8 6 4 2

Is 3S maintenance going on properly? 10 10 8 6 4 2

Maintenance, Work room

Are the management status of the equipment etc satisfactory enough?

10 10 8 6 4 2

Site Material Are the Material Map and Stock Management satisfactory enough?

10 10 8 6 4 2

Visual Management (VM)

Are the VM being done in the right time and place?

10 10 8 6 4 2

Learning Club (20)

Club Activity Are the activity and discussion contents being shared through the learning club?

10 10 8 6 4 2

VOC action How’s the status of action regarding VOC between operation and maintenance?

10 10 8 6 4 2

Improvement Activity

(20)

Regular Improvement Activity

Are the workers consistently finding loss and make improvement?

10 10 8 6 4 2

On Job Task Activity 과제의 선정및 내용이 적절하며, 성과가 있는가?

10 10 8 6 4 2

<Good Point> Total Appraisal 100 <To Be Improved>

4. ‘Choice of Quality’ Facility Certification

다. Request Form for ‘Choice of Quality’ Facility Appraisal (My Machine) Request Form for ‘Choice of Quality’ Facility Appraisal (My Machine)

(Appraisal Sheet Score as Reference)

Affiliation Team Name

중점 추진 내용

Facility Name Number of Team

Member

Activity Period Self Appraisal

Date

Appraisal

Request Date

Expected

Appraisal Date

Classification Item Score/Point

Self Appraisal

Basic Activity(Activity Board, Learning Club, etc) Point

Good Point

Facility

Improvement

Facility Improvement Score Point

Activity

Process

Loss Restoration

Rate %

Number of

Improvement 건

Number of OPL 건

Number of cleaning/

inspection tools improvement

건

Bad Point

Performance

Performance Score Point

Performanc

e Indicator

breakdown, accident

(disaster), defect

Total Score Point

4. ‘Choice of Quality’ Facility Certification

라. 명품 진단표(My Machine)

Affiliation Appraisal

Date

Activity Name Appraiser

Classification

Appraisal Item Appraisal Point Score Result S

(100%) A

(80%) B

(60%) C

(40%) D

(20%)

Basic Activity

(25)

5S Activity 3S maintenance condition is? 10 10 8 6 4 2

Learning Club Activity Are the contents of discussion and activity of the learning club being shared properly?

5 5 4 3 2 1

Usage of Activity Board

Are the contents of the activity displayed completely?

5 5 4 3 2 1

Safety Is the safety terms checking before doing a work is done in reality? (TBM)

5 5 4 3 2 1

Facility Improve

ment (35)

Finding 5 items of loss (Actual)

Standard of Loss Finding activity content and participation level is?

5 5 4 3 2 1

‘5 Loss’ recovery and improvement (Actual)

Are all loss being recovered? 10 10 8 6 4 2

Standard of improvement activity content and participation level is?

5 5 4 3 2 1

OPL Learning Standard of OPL learning level and contents is?

5 5 4 3 2 1

Cleaning(Inspection)Tools Development

Standard of number of tools development and the activity content is?

5 5 4 3 2 1

Visual Management (VM)

Is the VM applied at the right time and place?

5 5 4 3 2 1

Result (40)

Performance Indicator (Damage, accident, defect/fault)

Set up the target defiantly and achieve the target

15 15 12 9 6 3

Normal condition of the facility

Have the facility basic requirements (cleaning, 급유,체결) done in reality?

15 15 12 9 6 3

Maintaining and managing 기준서

Standards (cleaning, inspection, 급유) 작성 및 유지관리 상태는 양호한가?

10 10 8 6 4 2

<Good Point> Total Appraisal 100 <To Be Improved>

4. ‘Choice of Quality’ Facility Certification

Appraisal Item

Appraisal Main Item Output

설비점검청소

• 5S maintenance management condition

• 설비청소를 통한 설비의 제모습 찾기 정도

• The status of finding, restoring and improving five loss found in the facility

• Operators’ understanding level of facility’s structural function

• Improvement condition of cleaning tools

• Loss research

• Before-after improvement picture

• OPL

• 설비구조기능 이해시트

• Safety Requirements check sheet and TBM

• Improving cleaning tools

Facility Basic Improvement

• Found trouble source, troubled area in a facility

• Analyze the actual cause from the trouble source and troubled area (왜왜분석) and daily execution capability

• Result of countermeasure in the trouble source and troubled area

• Operator’s understanding level on facility structure

• Trouble source, troubled area research

• 왜왜분석 Sheet

• Picture before-after improvement

• Trouble source Map

Making Standard Operation

• State of loss, recovery and improvement on facility’s lubricating and fueling matters.

• Making standard operation for facility’s cleaning, inspection and fueling.

• Operator’s understanding level on facility structure.

• Understanding level on lubricating and fueling matters.

• Operator’s understanding level on facility cleaning, inspection and inspection standards and daily execution capability.

• Lubricating Maintenance Work Sheet

• Standard operation of cleaning, inspection and fueling and check sheet

• Picture before-after improvement

4. ‘Choice of Quality’ Facility Certification_ Appraisal Standard

구분 설비 점검청소 설비 기본개선 기준서 작성

Level 5

S(100%)

• 설비의 내외부가 깨끗하게 청소되어 있어, 설비가 처음 도입시 모습으로 복원되었음(100%)

• 오퍼레이터는 설비에서 낭비를 발굴하는 능력을 가졌고, 자신의 설비에 대한 이해를 매우잘 한 상태

• 발생원, 곤란개소의 완벽한 개선으로 재오염 이 발생하지 않는 설비가 구현되어 있음

• 청소 점검 등이 쉽고 짧은 시간내 가능(청소 점검등이 쉽고 최단시간내 실시가능토록 게선되어 있음)

• 오퍼레이터는 왜-왜 분석을 자유자재로 활용하여 문제에 대한 근본원인분석과 개선하는 능력을 매우 잘하는 상태

• 윤활,급유에 기인한 고장이 “0”화되어 있음 • 설비마다 청소점검급유 기준서가 완성되어

있음 • 오퍼레이터는 자신의 설비에 대한 완벽한 이

해 와 기준서 실행능력을 매우잘 갖춘 상태 • 설비의 눈으로 보는 관리가 완성된 상태 • 윤활,급유에 대한 이해가 매우 잘한 상태 • 마이머신 담당자에 의해 유지관리가 매우 잘

함

Level 4

A(80%)

• 설비의 내외부가 깨끗하게 청소되어 있어, 설비가 처음 도입시 모습으로 변화되었음(거의 대부분의 설비 내외부가 청소된 상태-80%)

• 오퍼레이터는 설비에서 낭비를 발굴하는 능력이 조금 부족하고, 자신의 설비에 대한 이해를 잘 한 상태

• 발생원, 곤란개소의 상당한 개선으로 재오염 이 적은 설비로 구현되어 있음

• 청소 점검 등이 쉽게 가능함(쉽도록 개선되어 있음)

• 오퍼레이터는 왜-왜 분석을 활용하여 문제에 대한 근본원인분석과 개선하는 능력을 잘하는 상태

• 윤활,급유에 기인한 고장이 극소화되어 있음 • 설비마다 청소점검급유 기준서가 완성되어

있음 • 오퍼레이터는 자신의 설비에 대한 많은 이해

와 기준서 실행능력을 잘 갖춘 상태 • 설비의 눈으로 보는 관리가 부분적 완성된 상

태 • 윤활,급유에 대한 이해를 잘한 상태 • 마이머신 담당자에 의해 유지관리가 잘함

Level 3

B(60%)

• 설비의 내외부가 조금 깨끗하게 청소된 상태(절반 정도의 설비 내외부가 청소된 상태-50%)

• 오퍼레이터는 부분적으로 자신의 설비에서 낭비를 발굴하는 수준이며, 설비의 이해는 처음보다 향상된 수준을 보이는 보통 상태

• 발생원, 곤란개소의 부분적 개선으로 재오염 이 적은 설비가 늘어나는 상태

• 오퍼레이터는 왜-왜 분석을 활용하여 문제에 대한 근본원인분석과 개선하는 능력이 보통수준 의 상태

• 윤활,급유에 기인한 고장이 현저히 줄어들고 있음

• 설비마다 청소점검급유 기준서가 완성되어 있음

• 오퍼레이터는 자신의 설비에 대한 이해가 부족하며, 기준서 실행능력이 보통인 상태

• 설비의 눈으로 보는 관리가 좋아진 상태 • 윤활,급유에 대한 이해가 보통인 상태 • 마이머신 담당자에 의해 유지관리가 보통

Level 2

C(40%)

• 설비의 외부는 조금 깨끗하게 청소되어 있음(일부 설비의 내외부가 청소된 상태-20%)

• 오퍼레이터는 설비에서 낭비를 발굴하는 능력 이 부족하고, 자신의 설비에 대한 이해가 조금 부족한 상태

• 발생원, 곤란개소의 개선이 부족해 재오염이 빈번하게 발생하고 청소를 통해 유지관리를 실시함

• 오퍼레이터는 발생원, 곤란개소의 의미를 조금 이해하고 왜-왜 분석을 통한 설비개선 이 부족한 상태

• 윤활,급유에 기인한 고장이 발생되고 있음 • 설비마다 청소점검급유 기준서가 부분적 완

성되어 있음 • 오퍼레이터는 자신의 설비에 대한 이해가 미

흡하고 설비의 기준서 실행능력도 부족 • 설비의 눈으로 보는 관리가 미흡한 상태 • 윤활,급유에 대한 이해가 부족한 상태 • 마이머신 담당자에 의해 유지관리가 부족

Level 1

D(20%)

• 설비의 내외부가 전혀 청소가 되어 있지 않음

• 오퍼레이터는 설비에서 낭비를 발굴하는 능력이 없고, 자신의 설비에 대한 이해가 아주 부족한 상태

• 발생원, 곤란개소의 개선이 많이 부족해 재오염이 발생하고 청소를 통해 유지관리를 실시함

• 오퍼레이터는 왜-왜 분석을 이해하지 못하고 단순한 청소만 반복하는 아주 부족한 상태

• 윤활,급유에 기인한 고장이 아직도 다발됨 • 설비마다 청소점검급유 기준서가 미완성상태 • 오퍼레이터는 자신의 설비에 대한 이해가 아

주 부족하고 설비의 기준서 실행능력도 아주 부족

• 설비 눈으로 보는 관리가 매우 미비한 상태 • 윤활,급유에 대한 이해가 매우 부족한 상태 • 마이머신 담당자에 의해 유지관리가 매우 부

족

4. ‘Choice of Quality’ Facility Certification_ Appraisal Standard

Step 1 2 3 4 5

Contents

Method EP Access Click ‘Sign’ Click ‘Sign Type’ Check Code Number

Request Amount

혁신지원그룹

※ Pipe flow sticker can be requested at Safety Disaster Prevention System and can be used after choosing and saving the department’s name (FromTo should be certainly recorded)

2

3 4

5

How to Apply For Sticker

Waste water

Kg/cm2

From To

CO

2

Kg/c

m2

Fro

m

To

Steam

Kg/cm2

From To

Sea Water

Kg/cm2

From To

H2

Kg/c

m2

Fro

m

To

Pipe Flow Sticker

Purge

Kg/cm2

From To

B.F.W

Kg/cm2

From To

Feed Gas

Kg/cm2

From To

1.Common

Sea water, waste water, recycled water

CO2, H2, OIL, Steam

2.Specifically for Utility, O2 Plant

Feed Gas, B.F.W,

Process Gas,

H2 Recycle,

Purge Gas,

Iginition Gas

3. Other type that has not been registered should be registered first before use

(Nameless sticker)

Pipe Flow Sticker

Regular Inspection/ Pressure Gauge Sticker

매월점검

매주점검

매월점검

매주점검

매월점검

매주점검

매월점검

매주점검

PULL

PUSH

P U L L

P U S H

FIXED

F I X E D

Door/ Rotation Direction Sticker