Run a 5S event in the pre-sort cabin

What is going on

The pre-sort cabin at Eastern Creek is where sorters pull bulky items, hazardous items, film plastic and contamination from the infeed belt before the optical sorters. The last monthly 5S audit scored 2.4 out of 5. Sharps containers are in three different places, the battery sand bin is at one end only, tongs go missing and the floor is cluttered with cardboard and personal items. Last week a smouldering lithium battery came through and a sorter had to run the length of the cabin to find the tongs. Luca Bianchi has given you and three other sorters Wednesday morning with the line stopped to run the first pass of 5S in the cabin, with Tomasz Nowak supporting.

Your brief

Run the sort, set in order, shine and standardise steps in the pre-sort cabin with the crew, red tag uncertain items, agree the location of every needed item including sharps containers, battery bins and tongs, write the cleaning and inspection standard, and record the improvement in the register with before and after evidence.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

• Read the 5S and standardised work procedure and the load acceptance procedure section on hazardous items, and take before photographs of the cabin.
• Run the sort step with the crew: remove everything not needed for sorting, red tag any item the crew cannot agree on and log the tags with date, area and reason.
• Agree the set in order layout so that sharps containers, battery sand bins, tongs, spill kit and gloves are within reach of every sorting position, and mark the locations.
• Clean the cabin and the belt guards and use the cleaning to inspect for damaged guards, loose handrails or blocked chutes, reporting any hazard found in the incident register.
• Write the cleaning and inspection standard for the cabin as a standard work document with steps, times and safety points, and agree it with Luca Bianchi.
• Take after photographs, re-audit the cabin with the 5S audit sheet and record the new score.
• Enter the improvement in the continuous improvement register with the before and after scores and photographs and present it at the next pre-start talk.

What someone in this role would produce

• Red tag log
• Marked layout with locations for every needed item
• Cabin cleaning and inspection standard work document
• Continuous improvement register entry with before and after audit scores