ABK – AOTS DOSOKAI 5 S Manual - Thiagarajar College

Thiagarajar College, Madurai - 625 009 (An Autonomous Institution Affiliated to Madurai Kamaraj University)

Re-Accredited with “A” Grade by NAAC

Ranked 34th

in NIRF 2019

Submitted to

ABK – AOTS DOSOKAI (Alumni Association of ABK & AOTS, JAPAN)

Tamilnadu

January 2020

5 S Manual

Thiagarajar College (Autonomous),

Madurai – 625 009 (Re-Accredited with ‘A’ Grade by NAAC )

Ranked 34t h

in NIRF 2019

DOC.NO: WMS-M-A/R1

DATE(ORIG): 20.06.2015

5S-WMS Table of content DATE(REV): 03.01.2020

PAGE.NO:

DATE : --------------- PREPARED BY. APPROVED BY.

Section No. Title Page No.

1 Introduction 01

2

5S Vision, Mission, Policy and Objectives 08

Organization chart 09

Roles and responsibilities - Core team 10

Layout 15

3 1S: SEIRI - Procedure 17

4 2S: SEITON - Procedure 28

5 3S: SEISO- Procedure 36

6 4S: SEIKETSU- Procedure 42

7 5S: SHITSUKE - Procedure 71

8 Benefits of 5S 95


Madurai – 625 009 (Re-Accredited with „A‟ Grade by NAAC )

Ranked 34t h

in NIRF 2019

DOC.NO: WMS-M-01/R1

DATE(ORIG): 20.06.2015

5S-WMS About the institution DATE(REV): 03.01.2020

PAGE.NO: 1


Thiagarajar College, founded on 7th July 1949, was formally inaugurated on 12th October

1949 by His Excellency, the King of Bhavnagar, the then Governor of Madras State. At the

inaugural function, the founder, Karumuttu Thiagarajan Chettiar, described this institution as a

"small and humble endeavour in education". The college, now has an impressive history

covering 65 epoch-making years.

From its inception, Thiagarajar College has been one of the premier institutions in Madurai. It

started with only three undergraduate courses, but now has grown in stature and offers 28 UG,

15 PG, 11 M.Phil. and 10 Ph.D. Programmes, in addition to 15 Diploma and 16

Certificate Courses.

The college is a private, aided, co-educational institution affiliated to Madurai Kamaraj

University. It is meticulously managed by the Kalaithanthai Karumuttu Thiagarajan Chettiar

Memorial Trust. The motto of the college is which means "Wisdom and love embody the

divine”.

The college has come a very long way from the time of its inception, with the significant

contribution of the founder, the great philanthropist Karumuttu Thiagarajan Chettiar, and the

committed service and support of the members of his family, the late Dr. Mrs. Radha

Thiagarajan (then Emeritus President), Mr. Karumuttu T. Kannan (President) Dr. Mrs. Uma

Kannan (Vice President) and Karumuttu K. Hari Thiagarajan (Secretary).

The focal points of the college are employability along with academic excellence and character

development. It aims at providing quality education, fostering excellence in research and

promoting academic inquiry. The college has been recognized as a Research Centre of

Excellence since 1978 and was upgraded as an autonomous institution in 1987. It was first

accredited Five Stars by the National Assessment and Accreditation Council (NAAC) in 2001

and was re-accredited ‘A’ Grade in 2007 and again re-accredited ‘A’ Grade in the third cycle



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in NIRF 2019

DOC.NO: WMS-M-01/R1

DATE(ORIG): 20.06.2015


PAGE.NO: 2


by NAAC in January 2013. The college has completed 33 years as an autonomous institution.

The college is certified by ABK-AOTS DOSOKAI with the Certificate of Achievement of

Best 5 S Practices in Educational Institution for two years from 2017 to 2019.

NAAC has recognized our Institution us one of the high performing institutions and has

extended the Accreditation validity period from five years to 7 years. The College got 44th

Rank in NIRF 2018 and has obtained 34th

Rank in NIRF 2019. The college has been selected as

a Mentor Institution under “PARAMARSH” programme by UGC.

The curriculum endeavours to integrate the acquisition of knowledge and career skills in the

student community. The teaching-learning systems have been further strengthened by nurturing

a creative environment so as to inspire out-of-the-box thinking and innovative solutions. The

learning process has been made more student-friendly through modern teaching aids and ICT

facilities, and accentuated with the students‟ participation in project work, on-the-job training,

internship, and e-learning. Moreover, in keeping with its aim of imparting a well-rounded

education, the college also plays an active role in creating an awareness of our

multidimensional heritage and culture.

Thiagarajar College provides an environment conducive for carrying out research projects, and

faculty members are encouraged to submit research proposals for grants from various funding

agencies like the UGC, DST, CSIR, DRDO, MoEF, MHRD, TNSCST, DBT, etc. The

college has been a member of the UGC-N-LIST (National Library and Information Services

Infrastructure for Scholarly Content) facility from the year 2010, and DELNET (Developing

Library Network). The faculty and research scholars utilize these facilities for their research.

Our college is a part of the cluster colleges selected by the CII (Confederation of Indian

Industry, New Delhi) for sharing of faculty and technical resources. Interdisciplinary research

is another healthy activity on the campus where research guidance and publication take place

between departments of related fields.



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The college is associated with organizations like Nottingham Trent University, United

Kingdom, National Taipei University of Technology, Taiwan, Birla Institute of Technology,

Goa Campus, M.S.Chellamuthu Trust, Madurai, IICT, Hyderabad, AIRC, Chennai, ICWAI,

Calcutta, and CECRI, Karaikudi, for research, and PARD, Madurai, AKASH, Madurai, Rotary

International, USA for outreach programmes. The Department of Economics has been

recognized by the Malcom and Elizabeth Adiseshiah Trust, Department of Econometrics,

University of Madras for awarding research grant to Ph.D., scholars. The Department of

Chemistry offers consultancy services in FTIR, UV and water analysis, as well as in Molecular

Modelling to the students, teachers, researchers and industries in South India.

All the students are expected to serve the community by enrolling themselves in the Physical

Education programme, NCC (Army, Navy), or NSS (for participation in community service).

The cultural programmes of the Fine Arts Club provide an opportunity for the students to hone

their skills in the performing arts. The Training and Placement Cell along with the Career

Guidance Cell and the Language Lab focus on personality development and ensure that all the

students receive soft skills training. The Women‟s Studies Centre, Rotract Club, Youth Red

Cross Society, Nature Club, Quality circles, Girls‟ Counselling Cell, Blood Donors Club and

First Aid Cell are the various clubs functioning to ensure the all-round development of our

students.

The college library is one of the oldest libraries in Madurai and houses a rare and valuable

collection of books. The general library and department libraries have a wide variety of text

books, Magazines, Journals various subjects. The library has a rare collection of ancient books

both in Tamil and English. The periodicals section has back-volumes of journals in all

disciplines.



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A first of its kind, the library has initiated an OPAC system (Online Public Access Catalogue

System) which helps the students access any book easily from any rack inside the library.

Students can avail themselves of guidance from our staff while searching for books. They can

also view their account details from the OPAC system on their own. The new version of the

periodicals display makes it easy to view and access journals and magazines.

The National Centre of Excellence on Statist ical and Mathematical Modell ing on

Bioresource Management was establ ished in 2013 , and received a grant of Rs.2 crores by

the Ministry of Human Resource Development, Government of India , New Delhi. It has

been recognized as a ful lt ime Research Centre by Madurai Kamaraj University for

carrying out multidiscipl inary research leading to Doctoral Degree. The centre offers

M.Sc., Biotechnology programme affi l iated to Madurai Kamaraj Universi ty. Further the

centre offers various training programmes in Mathematics and Biological Sciences

fulfi l l ing i ts objectives of Teaching, Training and Research. Establishment of a s ta te of

the art laboratory is in progress to facil i ta te researchers in mult idisciplinary area.

Our Institution is associated with the National Programme on Technology Enhanced Learning

(NPTEL), which was initiated by seven Indian Institutes of Technology (Bombay, Delhi,

Kanpur, Kharagpur, Madras, Guwahati and Roorkee) along with the Indian Institute of Science,

Bangalore in 2003. NPTEL, Largest online repository in the world of courses in engineering,

basic sciences and selected humanities and social sciences subjects was made available to the

students of our institution.

This premier institution is run entirely as a charitable non-profit institution

No donation and capitation fees for student admissions

Purely merit based selection in teaching and non teaching staff appointments

Traditional and heritage oriented campus culture in a safe environment

Well qualified and experienced faculty

Well equipped laboratories

Modern facilities and an atmosphere conducive to learning



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DATE(ORIG): 20.06.2015


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VISION AND MISSION OF THE INSTITUTION

Vision: To serve society by providing affordable quality higher education to all at all

times

Mission: To provide an academic ambience that offers equal opportunities to all and

ensures the efficient dissemination of knowledge through student-teacher synergy,

resulting in character development and career readiness.

OBJECTIVES OF THE INSTITUTION

To initiate students in higher learning up to research level by providing value based,

career oriented, quality education in a friendly ambience

To mould students for leadership, entrepreneurship and citizenship

To exemplify the highest standards with the help of committed and competent staff who

promote a need-based curriculum, innovative methodology and objective evaluation

To create self-confidence in the students and help them achieve academic excellence

Our objectives are communicated to the various stakeholders through our prospectus, website,

student orientation meetings, parent teacher meetings, staff meetings, and the mission statement

on display in various places in the campus.

Kalaithanthai Karumuttu

Thiagarajan Chettiar (Founder)

1893-1974

FOUNDER - Kalaithanthai Karumuttu Thiagarajan Chettiar

A visionary with a mission

A staunch nationalist

A great industrialist

An exceptional educationist

A social savant

A generous philanthropist

A crusading promoter of Tamil

Led a life of sacrifice



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Dr. Mrs. Radha Thiagarajan

(Emeritus President)

1926-2013

EMERITUS PRESIDENT - Dr. Mrs. Radha Thiagarajan

The first and two times Vice Chancellor of Alagappa

University

A multi-lingual scholar

A widely respected academician

A member of several prestigious bodies

A patron of religious and literary scholars

A generous contributor for noble causes

A devout person

Karumuttu T.Kannan

(President)

PRESIDENT - Karumuttu T. Kannan

Managing Director of Thiagarajar Mills Ltd., Madurai

Serves on several prestigious bodies which promote

industrial development and enhancement of skills for

societal change

Chairperson of the Trust that governs Arulmigu Meenakshi

Sundareswarar Temple, Madurai

Formerly Syndicate Member of Anna University

Formerly Member of Tamil Nadu State Planning

Commission, Chennai

An industrialist and entrepreneurial leader

An educationalist with 40 years of experience in education

administration



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Dr. Mrs. Uma Kannan

(Vice-President)

VICE-PRESIDENT - Dr. Mrs. Uma Kannan

Obtained a doctoral degree in Social and Cultural

Anthropology from Madurai Kamaraj University

Former Convener and Executive Committee member of

INTACH (Indian National Trust for Art, Culture and

Heritage)

Actively engaged in social causes

Qualified counsellor from Institute of Natural Healing -

London

Chairperson - Thiagarajar Crafts Foundation, Madurai,

which supports documentation and revival of local crafts.

Chairperson - Women's Studies Centre, Thiagarajar

College.

Mr. K. Thiagarajan (Secretary)

SECRETARY - Mr. K. Thiagarajan

Executive Director of Thiagarajar Mills Pvt Ltd

Director at VTM Limited, Virudhunagar

Part of Executive Council of the Young Indians (Yi)

Madurai Chapter

Part of COYD (Committee of Young Directors) SIMA,

Coimbatore

Member in the Committee of Administration of

TEXPROCIL (The Cotton Textiles Export Promotion

Council), Mumbai

Secretary of Thiagarajar College, Madurai

Member of the Textile Sector Skill Council (TSC), New

Delhi

Passionate about classical Tamil literature & Sanskrit



Ranked 34t h

in NIRF 2019

DOC.NO: WMS-M-02/R1

DATE(ORIG): 20 .06 .2015

5S-WMS 5S Vision, Mission, Policy and

Objectives

DATE(REV): 03 .01 .2020

PAGE.NO: 8

DATE : --------------- PREPARED BY. APPROVED BY

5 S Mission

To be a steward in the academic environment by adopting world class principles

for quality enhancement and to serve the student community in general, and the

economically backward students, in particular.

5 S Vision

Creating a clean, hygienic, standardized and self disciplined work culture

through team spirit by increasing the morale of teaching, non -teaching staff and

students for better academic excellence.

5 S Policy

Thiagarajar College ensures clean, healthy and hygienic academic ambie nce to

create and develop citizens of tomorrow through planned, disciplined, creative

and sustained quality initiatives.

5 S Objectives

- To increase the work space area by removing unwanted items in the institution.

- To maintain an orderliness in the institution.

- To create a clean and hygienic environment in the institution.

- To standardize the institutional academic, administrative and financial activities.

- To nurture self discipline and work satisfaction of the teaching, non-teaching staff and

students.

5 S Pledge

We, at Thiagarajar College, pledge to adopt high level of 5S policies and

principles for our individual and institutional development and ensure quality

enhancement and sustenance.



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DATE(ORIG): 20 .06 .2015

5S-WMS Organization chart DATE(REV): 03 .01 .2020

PAGE.NO: 9




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DOC.NO: WMS-M-04/R1

DATE(ORIG): 20 .06 .2015

5S-WMS Roles and responsibilities - Core team DATE(REV): 03 .01 .2020

PAGE.NO: 10


Secretary

Participating in policy formation

i) Helping to identify the need for 5S policy

ii) Assigning responsibilities

iii) Reviewing, revisiting and approving

To provide the strategies for 5S implementation.

To provide the needed resources.

Establishing the organisational infrastructure.

To review progress of 5S implementation two months once.

To motivate all levels of staff in 5S implementation.

To give recognition for best teams between staff areas.

Institute a vigorous program of education and retraining.

Drive out fear.

Break down barrier.

Institute leadership

5S Champion

Principal is the 5S champion

Reviews the 5 S activities at all levels with 5S Coordinators, Department level

Coordinators & Zonal and sub zonal coordinators at periodic intervals.

Educate 5S to all teams

Serve as a resource person to the teams

Keep the teams activities on the right track

Assist in the meeting process

Develop the skills and abilities of the team members, particularly leadership quality

Act as a liaison between team and the college

Extent help as and when needed

Help in creating a healthy atmosphere during team meetings

To give correct feedback and encourage the team.

Quality Control Coordinator

To register teams in the college and serve as storehouse of information on 5S

To have liaison with team leaders for ensuring regularity of 5S meetings, midterm

presentations.



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Convene steering committee meetings periodically and regularity atleast once a month

and circulate record notes of the meeting.

Appraisal to the steering committee on the functioning of 5S in the college.

To organize systematic documentation of 5S case studies, compile and publish them.

Arrange exchange of studies among different sister units or colleges.

To handle request for starting new 5S team

Organize training sessions for team leaders, 5S members serve as a faculty.

Arrange facilities for 5S team meetings

Organise management presentations and case study presentation of 5S outside the

college and also to the steering committee.

Monitor meetings of 5S teams regularly and suggest corrective actions needed.

Liaison with outside suppliers for 5S activities

To prepare training material for team leaders/members in association with training

department and constantly update them.

To expose all students at grass roots and different levels of staff to the concept of 5S in a

planned manner

To publish periodicals, pamphlets etc., for the promotion of 5S

To organize six monthly/ annual social get together of 5S members, team leaders and

steering committee members

Develop faculty for 5S programmes.

Organize annual conventions within the company.

To conduct periodical surveys on the health of 5S and present the findings to the steering

committee and also suggest remedial measures for discussion in the steering committee.

Organize for sponsoring and deputation of team leader, members for seminars,

competitions, conventions etc., outside the organisation.

Send a monthly report to all steering committee members, corporate coordinator and

other unit coordinator

Prepare 5S posters and display at important places of college

Prepare 5S magazine on the monthly basis and distribute to all staff and students

Prepare videos on the 5S implementation and telecast in local TV channels

Department Heads



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Translate the top management’s vision into reality

Find ways and means of balancing the demand for time and energy from different tasks,

enabling the employees to find the time needed for 5S from among the demands on their

time from routine or even critical and important activities.

Under no circumstances they should give an impression that 5S is less important than

other activities.

It is to be conveyed that 5S is like brushing one’s teeth and putting on clean presentable

clothes. It is part of one’s job and can be integrated with other activities.

They shall find time for doing 5S themselves.

They shall find time to ask others regarding progress of 5S in their respective areas

They should show concern for 5S progress

They should review regularly how it is going on.

They should become a part of the 5S structure and promote it.

Zonal & Sub zonal coordinators

Schedule- 5S team meetings

Decide the time frequency and duration of the meetings

Ensure effective participation of members

Prepare agenda for effective utilization of meeting.

Ensure that the problems discussed are 5S related problems.

Ensure the participation of all members.

Stimulate group discussion by giving necessary inputs and encouragement.

Conclude each meeting with the responsibilities and assignments clearly defined.

Ensure the minutes of meeting are properly recorded and distributed.

Arrange for management presentation

Maintain rapport with the facilitator

Plan the agenda to be meaningful and effective

Hold discussion with the facilitator before and after the meeting

Be responsible for students building

Encourage non-members to become members

Record the minutes of each meeting

Maintain the members attending log

Maintain a member training status record.



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Members

Attend all the meetings

Learn 5S techniques

Follow the code of conduct

Participate in the discussions

Follow 5S standards

Help to recruit new members for the team

Respect other members and cooperate with them

Learn to listen, appreciate, accommodate and assimilate others viewpoints or opinions.

Share 5S teams goals and objectives.

Interact with members freely

Do the homework before every meeting

Contribute to the success of the group

Steering Committee

A steering committee is a monitoring group headed by the principal of the

college, to review and improve the functioning of 5S.Th rough periodic and

regular reviews, the committee makes the functional heads accountable for the

healthy functioning of 5S in their area. Functional heads, in turn, would make

the leaders accountable.

Takes an overview of the operation of 5S in the college as a whole. On the basis of

reports from the coordinator and team leaders, problem areas are identified and remedial

action suggested.

Takes decisions on important recommendations of 5S falling outside the competence of

the other levels of management which are reported to the steering committee.

Gives major policy guidelines and directions for the healthy propagation of the concept.

Sanctions major programmes and financial support to give thrust to the promotion of the

5S.

Attends management presentations and get-together

Meets regularly once in two months as convened by the coordinator.

Auditing committee: (5S Coordinators)

Determine the need for and the purpose of the audit and initiates the process

Determines the general scope of the audit, such as what 5S system standard or document

it is to be conducted against

Receives the audit report



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Preparing the audit checklist

Determines what follow-up action, if any, is to be taken, and informs the auditee of the

actions to be taken.

Inform relevant employees about the objectives and scope of the audit.

Appoint responsible members of staff to accompany members of the audit team

Provide resources needed for the audit team in order to ensure an effective and efficient

audit process

Provide access to the facilities and evidential material as requested by the auditors

Cooperate with the auditor to permit the audit objectives to be achieved

Determine and initiate corrective actions based on the audit report.



Ranked 34t h

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DATE(ORIG): 20 .06 .2015

5S-WMS Layout DATE(REV): 03 .01 .2020

PAGE.NO: 15


College Layout



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DATE(ORIG): 20 .06 .2015

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1.Security Cabin

6.Secretary Office

11.Dept. of

Chemistry (Gr. Floor) & Physics

1st Floor

16.Litter Zone - Organic

21.Dept.

Zoology & Microbiology

26.Rain

Water Saving Pool

31.Dept. of

Economics

(Gr. Floor)

Dept. of Tamil (1st

Floor)

Dept. English (2nd

Floor)

36. Lotus Tank

2.Language

Lab

7.Conference

Hall

12.Chemistry

Research Room

17. Litter Zone -

Inorganic

22.NCC Army

& NCC

Navy (Gr.

Floor) Dept. Comp. Sci.

(1st Floor)

27.Men’s

Hostel 32.Library (3 Floors) 37.Post Office

3.College

Office

8.Main Hall

(Gr. Floor

Auditorium

& 1st Floor

Dept. of Botany)

13. Dept. of

Chemistry (Gr.

Floor) & Physics

1st Floor,

Controller of Examination

(Basement)

18. .Diamond

Jubilee Hall and

SRCC (Gr.

Floor)

Dept. of Busi. Admin. And

Maths (1st

Floor)

Dept. of

Commerce and Dept. of Bio. Tech

(2nd

Floor)

23.Women’s

Rest Room

28.RO Water

Plant

33.Library Reading

Room

(Gr. Floor)

Women’s Study

Centre (1

st Floor)

38.Canteen (Gr.

Floor)

Dept. of Physical

Education &

Tamil Music Research Centre

(1st Floor)

4.Principal’s

Office

9.Training &

Placement Cell

14.Lecture Halls 19.Women’s

Hostel

24.Water

Recycling Plant

29. Men's

Hostel

Dining Hall

34.Ladies Toilet 39. Generator

Room

5.IQAC /

DEAN 'S Office

10.Red Tag Area

15. Dr. Srimathi

Radha

Thiagarajan Auditorium

20. Women’s

Hostel Dining Hall

25. Compost Yard

30.Gents Toilet

35.Four & Two Wheeler Parking Area

40.Shade - net House



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DOC.NO: WMS-M-06/R1

DATE(ORIG): 20 .06 .2015

5S-WMS 1S: SEIRI - Procedure DATE(REV): 03 .01 .2020

PAGE.NO: 17


1S-SEIRI

Seiri - Sorting Strategy



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A red tag area is made available in every sub zone.

The items which are condemned are kept inside the red tag area with red tag.

Red tag is filled with the details about the item, the person responsible for decision

and the review date for decision

The items placed in the red tag area are registered in red tag area check list.

Items in the red tag area are disposed based on the decisions taken by the committee

members.

Formation of committee for disposal

Identify obsolete items like Equipment, furniture, machines, computer, books

purchased government grants.

List and place in an area with red tag in each and every department

Committee will physically verify the listed items

The details will be sent to UGC

With the approval from UGC, call for tender.



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Finalize the tender and the list will be sent to UGC for approval.

After approval same will be disposed and revenue will be generated.

The items placed in the red tag area are registered in the red tag area check list.

This checklist contains the date of sorting out, Name of the item, quantity and date of

disposal.

This checklist ensures proper disposal activity.



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Red Tag



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Old Record Room

Old record room has been created to keep the records which are not used but required for

statutory requirement and kept for reference.

Here also measures are taken for easy retrieval of records.



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Disposal Policy



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THIAGARAJAR COLLEGE, Madurai – 625 009

Name of the Department

Repor t o f surp lus , obso lete , and unserviceable s tores fo r Disposal .

GFR14, GFR15 AND GFR16 DELETED GFR17 (SEE RULE 196 ( i i i ) .

S

No Name of the

Equipments/

Asset

Qty Bill

No

Amount Purchase

Date Grant Remarks Page

No

1

2

3

4

5

Signature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Signature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Designation --- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Designat ion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Date - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Date - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

After completing the Seiri activities, to keep the Seiri condition live, to dispose off the

unwanted items in a continuous basis a plan has been formulated for every department

This plan tells the materials need to be removed, the frequency of removal, responsibility

to remove and the destination.

The disposal plan ensures the continuous implementation of 1S activity.



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SI.NO What to dispose Where

to

dispose

Who will

dispose When

to

dispose

How to

dispose

1. Damaged / Unwanted

files and papers,

Project files

Scrap yard Office

Sergeant

When

necessary

Move to

scrap &

Tender

2. Debries Scrap yard Civil

Engineering

Team

When

necessary

Move to

scrap &

Tender

3. Plastic i tems(pipes,

pipe fillings, buckets

and mug dustbins)

Scrap yard Office

Sergeant

When

necessary

Move to

scrap &

Tender

4. Damaged furniture Scrap yard Office

Sergeant

When

necessary

Move to

scrap &

Tender



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DATE(ORIG): 20 .06 .2015

5S-WMS 2S: SEITON - Procedure DATE(REV): 21 .10 .2019

PAGE.NO: 28




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PAGE.NO: 29




Ranked 34t h

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DOC.NO: WMS-M-07/R1

DATE(ORIG): 20 .06 .2015


PAGE.NO: 30




Ranked 34t h

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DOC.NO: WMS-M-07/R1

DATE(ORIG): 20 .06 .2015


PAGE.NO: 31




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PAGE.NO: 32


Before

After



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Fire Extinguisher Identification

Notice Board Separation to suit the display paper size



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PAGE.NO: 34




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Record Identification



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5S-WMS 3S: SEISO- Procedure DATE(REV): 21.10.2019

PAGE.NO: 36




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3S cleaning Checklist:



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CLEANING SCHEDULE

ZONE: Depar tment o f Business Adminis tra t ion

Checked by: Dr .P .Uma Rani (5 S coord ina tor)

S.n o . Zon e a r ea

( WHERE )

I t em / P lac e

( WH AT)

Fr eq u en c y

& Tim e

( WHE N)

Meth od o f

c l ean in g

(H O W)

C lean in g

t oo ls u s ed

Don e b y Resp on s ib l e

p ers on

( WH O)

1 HOD r oo m Flo or ,

Almi rah ,

Comp u ter

t ab le an d

Work t ab l e

Da i ly

0 8 .0 0 Hrs

S weep in g

an d

wip in g

Bro om an d

c lo th

Hou s ek eep in g

s t a f f

Dr .P . Uma Ran i

Zon e i n -ch a r g e

Roo f an d

E l ec t r i ca l

access or i e s

Mon th ly S weep in g

an d

wip in g

Web

c l ean in g

b ro omst i ck

an d c lo th

Hou s ek eep in g

s t a f f

Dr .P . Uma Ran i


2 S t a f f ro om Flo or ,

Almi rah s ,

Comp u ter

t ab le an d

Work t ab l e

Da i ly

0 8 .3 0 Hrs

S weep in g

an d

wip i n g

Bro om an d

c lo th

Hou s ek eep in g

s t a f f

Dr .P . Uma Ran i


Roo f an d

E l ec t r i ca l

access or i e s


an d

wip in g

Web

c l ean in g

b ro omst i ck

an d c lo th

Hou s ek eep in g

s t a f f

Dr .P . Uma Ran i


3 Dep a r tm en t

l i b ra r y

F lo or ,

Almi rah s

Da i l y

0 9 .0 0 Hrs

S weep in g

an d

wip in g

Bro om,

Han d b ru sh

an d c lo th

Hou s ek eep in g

s t a f f

Dr . D. An b u g eeth a


Roo f an d

E l ec t r i ca l

access or i e s


an d

wip in g

Web

c l ean in g

b ro omst i ck

an d c lo th

Hou s ek eep in g

s t a f f



4 C la ss ro oms F lo or an d

s t u d en t s d esk

Da i ly

1 .3 0 p .m.

S weep in g

an d

wip in g

Bro om an d

c lo th

Hou s ek eep in g

s t a f f

Dr .P . Th i l la i

Ra j an


Roo f an d

E l ec t r i ca l

access or i e s


an d

wip in g

Web

c l ean in g

b ro omst i ck

an d c lo th

Hou s ek eep in g

s t a f f





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PAGE.NO: 41


CLEANING SCHEDULE

ZONE: New block – Gents toilet

Checked by: Housekeeping supervisor

Zone

area (WHERE)

Item /

Place (WHAT)

Frequency

& Time (WHEN)

Method

of

cleaning (HOW)

Cleaning

tools

used

Done by Responsible

person (WHO)

Toilet Urinals,

Wash

basin

and

Floor

Twice in a

day

11.45 a.m

& 4.45

p.m (After

the break)

Brushing Hand

brush

and Mob

Housekeeping

staff

Housekeeping

supervisor

CLEANING SCHEDULE

ZONE: Gents toilet

Checked by: Housekeeping supervisor

Zone

area (WHERE)

Item /

Place (WHAT)

Frequency

& Time (WHEN)

Method

of

cleaning (HOW)

Cleaning

tools

used

Done by Responsible

person (WHO)

Toilet Urinals,

Wash

basin

and

Floor

Twice in a

day

11.45 a.m

& 4.45

p.m (After

the break)

Brushing Hand

brush

and Mob

Housekeeping

staff

Housekeeping

supervisor



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PAGE.NO: 42




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1.Staff Name Plate

Width = 1.5 inches

Length = 18 inches

Back ground colour : Green

Letter colour : White

2.Coding for Doors/Windows/ventilators Identification

I & II letter denotes the name of the Block

III Letters denotes Door/Window/Ventilator and then the Serial Number



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Room Size Identification

Width = 1.5 inches

Length = 12 inches

Back ground colour : Brown


Lecture Hall Name Boards

Width = 3 inches

Length = 18 inches



Lab Identification Board

Width = 6 inches

Length = 36 inches





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Switch Board Identification

Width = 0.5 inches

Length = 0.75 inches



Fan Identification

Diameter: 3 inches

Back ground colour: Green




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Tube Light Identification

Diameter: 3 inches



Vision Mission Board

Length: 3 feet

Height: 5 feet





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Sign Board

Length: 3 feet

Height: 4 feet





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Sign Board

Length: 3 feet

Height: 4 feet

Back ground colour : Blue




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Faculty Profile Board

Length: 3 feet

Height: 5 feet





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Class Timetable Board – Aided

Length: 4 feet

Height: 3 fee t

Back ground co lour: Green & Blue

Let ter co lour : Whi te

Class Timetable Board – Self Finance

Length: 4 feet

Height: 3 fee t

Back ground co lour: Green & Red

Let ter co lour : Whi te



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Courses offered & Students Strength Board

Length: 4 feet

Height: 3 feet


Letter colour : White & Yellow

Class Mentors Details Board

Length: 4 feet

Height: 3 feet


Letter colour : White & Yellow



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5S Audit Score Board

Length: 4 feet

Height: 3 feet



Width = 30 inches

Length = 8 inches

Back ground colour : Red




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Students Instruction Board

Length: 3 feet

Height: 5 feet





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Library Sign Boards

Length: 1.5 feet

Height: 1 feet



Length: 1.5 feet

Height: 1.5 inches





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Books Storage Identification

Length: 1.5 feet

Height: 2 inches



Assets Identification

I Letter denotes the name of the Department

II Letter denotes the name of the Material

III Letter denotes the name of the Asset and then the Serial Number



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Trees Specification and Identification

Rain Water Harvesting System



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Rest Room Identifications

Length: 18 inch

Height: 3 inches



Staff table 1s t

Draw Template (Proposed)

Length: 18 inches

Height: 12 inches



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Fire Extinguisher Identification

Back sheet with yellow black zebra lines

Fire extinguisher number on the wall and fire extinguisher

Red white zebra lines on the floor below the fire Extinguisher



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PAGE.NO: 59


Thiagarajar College, Madurai

5 ‘S’ Internal Audit – Opening Meeting

Date: ___________________ Time: __________

Present: _________________

S.No Name Designation Signature

Agenda Introduction / Scope of Audit

Brief Status Report by 5 „S‟ Coordinator

Audit Schedule:

5’S’ Gemba Audit Plan

Remarks, if any



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Thiagarajar College, Madurai

5 ‘S’ Internal Audit – Closing Meeting

Date: ___________________ Time: __________

Present: _________________

S.No Name Designat ion Signature

Agenda Introduction / Scope of Audit

Brief Status Report by 5 „S‟ Coordinator

Audit Schedule:

5’S’ Gemba Audit Plan

Remarks, if any



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PAGE.NO: 61


5S Assessment Criteria Framework CRITERIA Max.

Marks

Awarded

Marks

Remarks

1 5S LEADERSHIP

1.1 5S Understanding of Executives:

General Awareness

Executive Involvement

20

20

1.2 5S Understanding of Supervisory and Front

Line Employees:

General Awareness

Involvement

10

10

1.3 5S is included as part of monthly pro gress

review:

Evidence of discussions (Agenda,

minutes, etc)

Evidence to follow up

10

10

1.4 Orderliness and cleanliness of gate /

entrance / lobby areas and first impressions

to a visitor:

Entrance area

Lobby area

10

10

TOTAL 100

2 SEIRI

2.1 Outside area within the premises free of

clutter

Garden areas free of clutter

Exterior storage free of clutter

Outside areas clearly marked

10

10

10

2.2 Floor area of buildings free of unwanted

items

All floors cleared

WIP demarcated

10

10

2.3 Tops and insides of all cupboards, shelves,

tables, drawers, etc. free of unwanted items

(In all locations)

30

2.4 Items are stored according to frequency of

use

20

2.5 Notice Boards are free of old notices: 20



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PAGE.NO: 62


2.6 Rules for disposal (Habitual Seiri) and

detecting non moving stocks are evident

and are adhered to:

Red labeling being done

Disposal standards maintained

Regular clearing of all storage areas

Regular removal of garbage and

waste bins

10

10

10

10

2.7 There is a general clutter free appearance:

Outside

Office areas

Stores

Table tops and work table tops

10

10

10

10

TOTAL 200

CRITERIA Max.

Marks

Awarded

Marks

Remarks

3 SEITON

3.1 Direction indication are available to all

facili ties from the entrance onwards :

Main entrance onwards

Inside all buildings

To all facilities, toilets, etc

5

5

5

3.2 All machines have identification labels 10

3.3 All buildings, rooms, cubicles and similar

areas are clearly numbered or named:

Rooms, departments, units marked

Toilets, canteens, etc. marked

5

5

3.4 All equipments / tools / files etc. are

arranged according to the „can see‟, „can

take out‟, „can return‟ principle. File

index maintained:

Outlines marked

Filing cabinets labeled

Office fi le index available

5

5

5

3.5 There are „visual control‟ methods for

defects and rework:

Markings to prevent mix-up

Markings to enable display

highlighting magnitudes

10

10



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3.6 All gangways area clearly marked and

respected:

Passageways

Entrance and exit lines

Curved door opening lines

Direction of travel arrows

5

5

5

5

3.7 Parking areas are specified and marked for

vehicles, pallets, trolleys, garbage bins,

etc.:

Reserved seat method for al l

movable items

For all office equipment

10

10

3.8 Specific areas are demarcated for garbage

/ rejects / waste etc.

15

3.9 Switches, fan regulators, controls, etc

labeled

10

3.10 All cables, wires, pipes, etc. are neat and

straight

10

3.11 Colour coding is used effectively for easy

identification

20

3.12 All stores are well maintained with racks,

bins and other storage areas clearly

marked

20

3.13 There is a general appearance of

orderliness and ability to find any item /

document without delay

10

TOTAL 200

CRITERIA Max.

Marks

Awarded

Marks

Remarks

4 SEISO

4.1 Cleanliness of outside premises

maintained at a high level

Free of litter

Cleaned regularly

5

5

4.2 A waste bin strategy is implemented:

Bins at regular interval

Marked

10

10



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PAGE.NO: 64


4.3 Toilets are well maintained

In working order

Clean

10

10

4.4 Canteen, rest rooms / locker rooms are

well maintained

Clean

Orderly

10

10

4.5 Floors, walls, windows, etc. are

maintained at a high level of cleanliness:

Floors

Walls

Windows, doors

10

10

5

4.6 Use of adequate cleaning tools is evident 10

4.7 Storage of cleaning tools well done:

Hanging brooms, mops

Other equipment properly stored

5

5

4.8 Machines, equipment, tools, furniture

maintained at a high level of cleanliness,

maintenance schedules displayed:

Maintenance schedules mainta ined

Cleaning with checking checklist

maintained

10

10

4.9 Daily self cleaning ( min / 5 min) is

practiced:

Daily activity

Checklist is used

10

10

4.10 Cleaning responsibil ity maps and

schedules are displayed:

Cleaning responsibil ity maps are

displayed

Cleaning schedules displayed

10

10

4.11 There is a general appearance of

cleanliness all round

25

TOTAL 200



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PAGE.NO: 65


5 SEIKETSU

5.1 All 5S procedures are standardized 10

5.2 Checklists are used to regularly inspect 10

5.3 All labels, notices are standardized 10

5.4 All aisles / gangways have a standard size and

colour

10

5.5 Standard Visual Management is evident

Okay marks

Danger Zone marked

Open and shut directional labels

Oil labels

5

5

5

5

5.6 Fire extinguishers are clear ly marked and

placed

Type indicated

Easily accessible

Visible at a distance

Checked at appropriate intervals

5

5

5

5

5.7 Standard warning signs

Prohibition sign

“Must Do” sign

Danger sign

Safe way sign

5

5

5

5

5.8 Pipes, cables, etc. are colour cod ed according

to a standard

10

5.9 Standardised checking procedure id adopted 20

5.10 Innovative visual control methods are

implemented

20

TOTAL 150



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PAGE.NO: 66


6 SHITSUKE

6.1 There are regular training programmes:

Evidence of training

Evidence of follow up

10

10

6.2 There is a 5S patrol team which regularly

reviews:

Teams named and used regularly

Results / photos of inspections displayed

Good examples displayed

5

5

5

6.3 There are 5S posters and 5S point of work

reminders

Posters at workplaces

Posters in the canteen

Point of work reminders

10

10

5

6.4 There is a system of strict discipline and

encouragement with „good point‟ and „bad

point‟ stickers

10

6.5 Self discipline amongst the entire workforce is

evident

20

6.6 There are 5S teams engaged in 5S projects

Small group activities (e.g. QCC)

Kaizen suggestion schemes

Team projects displayed

10

10

10

6.7 There are sustenance programmes such as

slogan competitions

Slogan competitions

Poster competitions

Interdepartmental competi tions at least

one in 4 months

10

10

10

TOTAL 150

GRAND TOTAL 1000



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DOC.NO: WMS-M-09/R1

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PAGE.NO: 67


5S Cross - Audit scores

Departments

July

2017

Oct

2017

Jan

2018

Apr

2018

July

2018

Oct

2018

Jan

2019

Apr

2019

Tamil 271 625 346 406 465 439 654

English 379 586 495 482 588 462 522

Economics 395 594 427 417 552 399 426

Busi.Admn 516 555 519 566 596 627 631

Commerce 629 671 569 576 603 693 733

Mathematics 516 529 457 532 576 642 645

Physics 327 ___ 360 518 661 379 360

Chemistry 438 ___ 568 534 584 628 717

Botany 460 ___ 462 622 486 519 521

Zoology 454 436 544 551 605 515 565

Comp.sci 518 574 448 533 673 566 643

Psychology 096 216 255 254 304 152 99

Biotech 257 528 707 669 698 648 570

CA & I.T 216 550 726 571 537 582 525

Office 229 ___ 222 328 291 397 569

Library 318 ___ 364 431 459 547 584

COE Office 531 561 494 509 532 555 781

Phy.Edn 339 ___ 603 735 546 534 534

Men‟s Hostel 624 ___ 636 668 646 583 545

Women‟s

Hostel

611 619 549 683 720 721 701



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PAGE.NO: 68


Audit Scores - Graph



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PAGE.NO: 69




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PAGE.NO: 70


Thiagarajar College (Autonomous)


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5S-WMS 5S: SHITSUKE - Procedure DATE(REV): 21.10.2019

PAGE.NO: 71




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PAGE.NO: 72


5S –Principles and Practices – Orientation Programme

Students -5S Orientation programme



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PAGE.NO: 73


5S Auditors Training Programme

State Level Student’s Seminar on Implementation of 5S Principles in

Corporate Sector



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PAGE.NO: 74


Training Programme for 5S Student Champions (Aided & Self Finance)…



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PAGE.NO: 75


External Auditor-Auditing Hours

Internal Auditor-Auditing



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PAGE.NO: 76


Learning the 5S Implementation Experience at Kongunadu College of Engg

& Tech

5S – Presentation by Student

5S Poster- Competition



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PAGE.NO: 77




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PAGE.NO: 78




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PAGE.NO: 79




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PAGE.NO: 80


5S Internal Awards

5S External Awards



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PAGE.NO: 81


5S Audit Plan:

Self Audit – Once in a Month

Cross Audit – Once in Two Month



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PAGE.NO: 82


Thiagarajar College, Madurai – 09

5S Workplace Management Activ ities

5S Audit Plan- 2017



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PAGE.NO: 83


5S Training Plan / Meetings:

Thiagarajar College, Madurai -09

5S Workplace Management Acitivities

5S Training Plan – 2017

5S – Sustenance Activities



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PAGE.NO: 84




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PAGE.NO: 85




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5S INTER DEPARTMENTAL ESSAY WRITING COMPET ITION

TOPIC: 5s Practices in -A March towards a Better Liv ing Environment

Number of Part ic ipants - 76



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PAGE.NO: 88


5S Certificate of Achivement



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PAGE.NO: 89




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5S Signature Campaign



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PAGE.NO: 91


5S Consultancy



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Programmes

Date Programme

28.01.2015 5 S Auditor‟s Training Programme by Mr.B.Sivarama Reddy – 5 S

expert

22.03.2016 Visit to Kongunadu College of Engineering and Technology,

Thottiam.

20.04.2016 5 S Orientation Programme to Non-teaching staff

26.09.2016 5 S Auditor‟s Training Programme by Mr.P.M.Devarajan,

Hon.Secretary, Quali ty Circle Forum of India, Hosur sub chapter,

Hosur

29.06.2017 Training programme on “5 S Principles and Practices of

Housekeeping” for 5 S student champions (Aided and Self -

financed stream)

20.07.2018 Orientation Programme on “Quality Circles” to students

27.12.2018 Orientation Programme on “Quality Circles” to students

01.02.2019 Review meeting on “Quality Circles”



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Meetings/preliminary and final audit

Date Programme

04.07.2014 Meeting – Implementation of 5 S in model department s:

Department of Botany; Department of Zoology; College Office;

and Library

25.07.2014 Review meeting – Implementation of 5 S













09.02.2016 Steering meeting /Orientation Programme on “Extension of 5 S

implementation to all academic and service departments”

09.02.2016 Orientation meeting to 5 S coordinators of all departments








19.04.2017 5 S Certification Audit pre-requisites meeting


11.07.2017 5 S Certification Audit - Steering committee meeting


19.09.2017 Preliminary audit pre-requisites meeting

21.09.2017 Preliminary audit by ABK-AOTS, DOSOKAI, JAPAN, TN Centre

04.10.2017 Preliminary audit feedback meeting



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DATE(ORIG): 20.06.2015


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24.10.2017 5 S Certification Final audit pre-requisites meeting and

conformance of the preliminary audit meeting

27.10.2017 5 S Certification Audit - ABK-AOTS, DOSOKAI, JAPAN, TN

Centre

21.12.2017 5 S Certification – Achievement meeting for 5 S coordinators

03.01.2018 5 S Certification – Achievement meeting for Non-teaching staff

15.02.2018 5 S Sustenance review meeting

20.07.2018 Orientation Programme on “Quality Circles” to 5 S coordinators






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in NIRF 2019

DOC.NO: WMS-M-11/R1

DATE(ORIG): 20 .06 .2015

5S-WMS Benefits of 5S DATE(REV): 03 .01 .2020

PAGE.NO: 95


Benefits of 5S - Solution, Implementation and Gain : A Disposal policy, with time period, has been finalized and implemented. By

implementing the disposal policy, more space – 5 racks and 6 Almirahs in the College

Office; and 4 racks and 7 almirahs in the Library; was made available for staking.

Around 250 very old files/records (Staff leave letters, TPF files, etc.,)

pertaining to period before 2004 were identified and sorted for disposal.

Very old College records such as Student Attendance registers, Identity cards,

Students requisition letters, Annual magazines, Seithi-madal, Calendars are removed

from the record room and kept for disposal.

Obsolete Equipments such as Typewriters, Dot matrix printers and monitors

which are to be scrapped/condemned are removed and kept in the Red tag area for

disposal.

More space is available after 1S implementation for record maintenance.

As the files and almirahs are labeled, It becomes easier for locating and

retrieving files and records.

5-S Mission, Vision, and Objec tives for the institution was framed.

5-S organization chart was framed and displayed in the 5 -S Notice

board.

Old Steel almirahs are replaced with new steel almirah in the model

departments

Filing system and Record administration was updated - Box files were

introduced and flat files were replaced.

Periodic audit ing (Self -audit and Cross-audit) was undertaken with the

framed Checklist and displayed in the 5 -S Audit Score board.

Assets (Doors, Windows, Ventilators, Black boards and Furniture) are

labeled with asset identification number.

Fire Extinguishers and Electrical fittings are labeled for easy accession.



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DOC.NO: WMS-M-11/R1

DATE(ORIG): 20 .06 .2015


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Hall number and names, Department profile, Classroom time -table was

standardized and displayed.

Dustbins were placed in the classrooms, verand ah and in the open area

of the College campus and cleanliness was insisted among the Student

community.

Electric bells are fitted and the Lecture time schedule was standardized.

Professional cleaning contract was undertaken for better college

ambience.

Auditors Training programme; Students orientation programme on 5 -S

and Mass cleaning programme were also organized.

For every apparatus in the laboratory, a system of Standard Operating

Procedure was displayed.

Station numbers are displayed in the laborator y for easy accession of

students .

A well designed storage plan is drafted and displayed.

Cleaning schedule and cleaning checklist was displayed in various

zones.

A professional 5 S Work Management System followed by the

stakeholders of the institution helps to inculcate discipline in the

mindset of the students, the citizens of our Nation.

A clean and tidy workplace leads to greater well being and increased

motivation.



Ranked 34t h

in NIRF 2019

DOC.NO: WMS-M-11/R1

DATE(ORIG): 20 .06 .2015


PAGE.NO: 97


List of Formats Used

1. Red Tag / Red Tag register

2. Disposal policy

3. Audit Checklist

4. Cleaning Checklist

5. Training Calendar

6. Audit Plan

7. Before and After Fixed Point Photographs

ABK – AOTS DOSOKAI 5 S Manual - Thiagarajar College

Documents

Transcript of ABK – AOTS DOSOKAI 5 S Manual - Thiagarajar College