Chapter 4

SHINE WORK AREA

For dream science and technology college 1st year

pharmacy level three students

Prepared by Abel Abebe (BSCN)

• upon completion of this chapter, you will be
able to:
Keep the work area clean and tidy
Perform regular housekeeping and Inspection
activities
4.1 Explanation of Shine

4.1.1 Definition of Shine

• The third pillar of 5S is shine. Shine means sweeping

floors, wiping off machinery and generally making
sure that everything in the factory stays clean.

• In a manufacturing company, shine is closely related

to the ability to produce quality products. Shine also
includes saving labor by finding ways to prevent dirt,
dust, and debris from piling up in the workshop.
 Cont…
• Shine should be integrated in to daily maintenance
tasks to combine cleaning checkpoints with
maintenance checkpoints.

• Cleaning is so important because when we clean an

area, we are also doing some inspection or checking
of machinery, equipment, and work conditions.
 Con t…..
• While cleaning the machine, however, one can easily
spot oil leakage, a crack developing on the cover, or
loose nuts and bolts. Once these problems are
recognized, they are easily fixed.

• An operator cleaning a machine can find many mal-

functions. When a machine is covered with oil, soot,
and dust, it is difficult to identify any problems that
may be developing
 Cont….

• It is said that most machines breakdowns begin with

vibration (due to loose nuts and bolts), with
introduction of foreign particles such as dust or with
inadequate oiling and greasing.
• For this reason shine is useful to make discoveries
while cleaning machines. Hence, shine means
cleaning the workplace’s floors, equipment and
facilities, provide inspection at the same time, and
ensure that they are in good operating condition.
 4.1.2 Benefits of shine
• One of the more obvious purposes of shine is to turn
the workplace in to clean, bright place where
everyone will enjoy working.

• Another key purpose is to keep everything in top

condition so that when someone needs to use
something, it is ready to be used.
 Cont…..
• Companies or organizations should avoid the
tradition of annual at the end of the year or
on spring cleanings. Instead, cleaning should
become a deeply ingrained part of daily work
habits, so that tools, equipment, and work
areas will be ready for use all the time.
 Cont…..
• Cleanliness for factories and offices is a lot like
bathing for human beings. It relieves stress and
strain, removes sweat and dirt, and prepares the
body and mind for the next day. Cleanliness is
important for physical and mental health. Just as you
would not bath only once a year, performing shine
procedures in a factory should not be an annual
activity. Cleaning should be done on daily basis.
 Cont……
• Shine activities can play an important part in
bringing work efficiency and safety. Cleanliness
is also linked with the morale of employees and
their awareness of improvements. Factories or
workshops that do not implement the shine
pillar suffer the following types of problems:
1. Poor morale and inefficiency at work. This
could be due to dirty windows that can pass
only little light.
2. Unable to see or find defects in dark and
messy workplaces.
 Cont….

3. Slipping and injuries can be created due to puddles of oil

and water on the floor
4. Frequent breakdown of machines due to insufficient check-
ups and maintenances which in turn leads to late
deliveries.
5. Low and unsafe operating machines due to insufficient
checkups and maintenance which in turn leads to hazard
and accidents.
6. Defects will result due to shaving cuts getting mixed in to
production or assembly processes.
7. Shaving cuts can get in to people’s eyes and create injuries.
8. Low morale due to filthy work environments.
 4.2 Implementing Shine

• 4.2.1 Plan and procedures for shine activities

• Shine activities should be taught as a set of steps and rules

that employees learn to maintain with discipline.

Procedures for shine

 determine shine target area

 determine shine assignments
 Determine shine methods
 preparing proper tools for shine
 start to shine
 Cont…..

Step 1 Determine shine target areas

Shine target areas are grouped in to three
categories:
 warehouse item,
 equipments and
 space.
 Warehouse items include raw materials, procured
subcontracted parts, parts made in-house, and
assembly components, semi-finished and finished
products.
 Cont….

• Example of warehouse item in hospital

 Cont……

• Equipment includes machines, welding tools,

cutting tools, conveyance tools, general tools,
measuring instruments, die and castes,
worktables, cabinets, desks, chairs and spare
equipment.
• Space refers to floors, work areas, walkways,
walls, pillars, ceilings, windows, shelves,
closets, rooms and lights.
 Cont…..
Step 2 Determine Shine Assignments
• Workplace cleanliness is the responsibility of everyone
who works there. Each employee should be assigned
specific area to clean. To do this two methods can be
used:
• A 5S Assignment Map – shows all the target areas for
shine activity and who is responsible for cleaning them. By
marking on 5S Map, the shine assignments can be shown.
• A 5S schedule – shows in detail who is responsible for
cleaning which areas on which days and times of the day.
Then this schedule should be posted in the work area.
 Cont….

Step 3 Determine shine methods

• Shine activities should be a natural part of the daily
work. Shine activities and inspection should be done
before a shift starts, during work time and at the end
of the shift.
• Determining shine methods include:
• Choosing targets and tools – define what will be
cleaned in each area and what supplies and
equipment’s will be used.
 Cont….
• Performing the five-minute shine – cleaning
should be practiced daily and should not
require a lot of time.
• Creating standards for shine procedures –
people need to know what procedures to
follow in order to use their time efficiently.
Otherwise, they are likely to spend most of
their time getting ready to clean.
 Cont….

Step 4 prepare tools

• The cleaning tools including brooms, brushes,
vacuum cleaner, trash basket, mop, dust collector
etc… should be placed properly or set in order where
they are easy to find, use and return.
Step 5 Start to shine
• When implementing the shine procedures, consider
the following suggestions:
 Cont….
• Be sure to sweep dirt from floor cracks, wall corners,
and around pillars.
• Wipe off dust and dirt from walls, windows, and
doors.
• Be thorough about cleaning dirt, scraps, oil, dust,
rust, cutting shavings, sand, paint, and other foreign
matter from all surfaces.
• Use cleaning detergents when sweeping is not
enough to remove dirt.
 4.3 Regular Housekeeping Inspection Activities

• As discussed earlier, it is natural to do a certain

amount of inspection while implementing shine
activities.
• Once daily cleaning, during shift and periodic
major cleanups become a habit, we can start
incorporating systematic inspection procedures in
to the shine procedures.
• Even when equipment in the workplace appears to
function normally, it may be developing many
problems.
 Cont….

• Always when machines or other equipment begin to

show sign of minor, sporadic malfunctions, the
operators not the maintenance people notice it first.
Therefore, it is important to consider the operators
information about the equipment.
 Cont….
• The following types of equipment problems
frequently exist in factories:
• Oil leaks from the equipment on to the floor.
• Machines are so dirty that operators avoid
touching them.
• Gauge displays and other indicators are too
dirty to be read.
• Nuts and bolts are either loose or missing.
 Cont….

• Motors overheat.
• Sparks flare from power cords.
• V-belts are loose or broken.
• Some machines make strange noises.

 Daily cleaning or inspection can help to find

these problems and solve them.
 Cont….
4.3.1 Inspection steps
• The steps of inspection and shine procedures are
parallel. But the steps of inspection give greater
emphasis on the maintenance of machines and
equipment. These steps are:
Step 1: Determine inspection targets
• The targets for inspection are similar to the targets of
shine activities. These include machines, equipment,
jigs, dies, cutting tools and measuring instruments.
 Cont….
Step 2: Assign inspection activities
• In principle, the people who carry out inspection
on a particular machine should be the same
people who operate the machine. But most often
one person can operate several machines at a time
In this case, it is good to involve line supervisors
and group leaders in the inspection duties.
• Once inspection activities are assigned, they have
to be written up on a large signboard for the
workshop or on small signboards that are attached
to each target machine.
 Cont….
Step 3: Determine inspection methods
• First all of the items to be inspected should be
listed then an inspection checklist should be
prepared based on the listed inspection items.
• Step 4: Implement inspection
• When implementing inspection, use all your
senses to detect abnormalities. Inspection is
not simply a visual activity. There are some
ways to detect abnormalities. These are:
 Cont….
• Look closely at how the machine works and watch
for slight defects (e.g. oil leakage, debris scattering,
deformation, wear, warping, mold, missing items,
lopsidedness, inclinations, color changes).
• Listen closely for changes in the sounds the
machine makes while operating (e.g. sporadic
sounds, odd sounds).
• Touch the machine where it is safe during operation
and during downtime to detect deviations from
normal conditions (e.g. strange vibrations,
wobbling, looseness, excessive heat, shifting).
 cont….
• Use your nose to detect burning smells or other unusual
odours (e.g. burning rubber)
Step 5 Correct equipment problems
• All equipment abnormalities or slight defects should
be fixed or improved. There are two approaches to do
these:
• Instant Maintenance: whenever possible, an
operator should immediately fix or improve a
problem he or she discovers during inspection. But
the operators should know what level of maintenance
work they can handle by themselves and
immediately.
 Cont…
• Requested Maintenance: In some cases, a defect
or problem may be difficult for the operator to hand
alone and immediately. In this situation, the operator
should attach a maintenance card to the site of the
problem in order to make it visible. He or she can
also issue a maintenance kanban to request help
from the maintenance department.
Thank you