Common UC 6 - Performing shop maintenance

HOW TO USE THE MODULE

Welcome to the Module
“PERFORMING SHOP MAINTENANCE”.
This module contains training materials and activities for you to complete.

The unit of competency
“PERFORM SHOP MAINTENANCE”
contains knowledge, skills and attitudes required for a Driving NC II course.

You are required to go through a series of learning activities in order to
complete each of the learning outcomes of the module. In each learning
outcome there are Information Sheets, Task Sheets and Activity
Sheets. Follow these activities on your own and answer the Self-Check
at the end of each learning activity.

If you have questions, don’t hesitate to ask your teacher for
assistance.
Recognition of Prior Learning (RPL)

You may already have some of the knowledge and skills covered in this
module because you have: been working for some time o already have
completed training in this area.

If you can demonstrate to your teacher that you are competent in
a particular skill or skills, talk to him/her about having them formally
recognized so you don’t have to do the same training again. If you have a
qualification or Certificate of Competency from previous trainings show
it to your teacher. If the skills you acquired are still current and relevant
to this module, they may become part of the evidence you can present
for RPL. If you are not sure about the currency of your skills, discuss it
with your teacher.

After completing this module ask your trainer/facilitator to assess
your competency. Result of your assessment will be recorded in your
competency profile. All the learning activities are designed for you to
complete at your own pace.

Inside this module you will find the activities for you to complete
followed by relevant information sheets for each learning outcome. Each
learning outcome may have more than one learning activity.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 2

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE

MODULE TITLE : PERFORMING SHOP MAINTENANCE

MODULE DESCRIPTION: This unit deals with inspecting and cleaning of
work area including tools, equipment and
facilities. Storage and checking of
tools/equipment and disposal of used materials
are also incorporated in this competency.

NOMINAL DURATION : 4 hours

CERTIFICATE LEVEL : NC II

PREREQUISITE : none

SUMMARY OF LEARNING OUTCOMES:
Upon completion of this module, the trainee/student must be able to:

LO 1. Inspect/clean tools and work area.
LO 2. Store/arrange tools and shop equipment.
LO 3. Dispose waste and used lubricants.
LO 4. Report damaged tools and equipment.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 3

LO1. INSPECT/CLEAN TOOLS AND WORK AREA

ASSESSMENT CRITERIA:

1. Use cleaning solvent as per workshop/tools cleaning requirement.
2. Check and clean work area.
3. Wipe and dry wet surface/spot in work area.

CONTENTS:

1. Workshop policies.
2. Types and usage of cleaning chemicals.
3. Safe handling of equipment and tools.
4. Service procedures.
5. Equipment maintenance standards.

CONDITIONS:

Students/trainees must be provided with the following:
1. Open workshop/garage
2. Well ventilated enclosed work and office area
3. Wash area and mess hall
4. Cleaning chemicals
5. Inventory of equipment and tools
6. Rugs
7. Containers for used oils
8. Vehicle
9. Oiler

METHODOLOGIES:

1. Lecture
2. Demonstration
3. Self-paced instruction
4. Dual Training

ASSESSMENT METHODS:

1. Direct Observation
2. Practical
3. Interview
4. Written examination

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 4

LO2. STORE/ARRANGE TOOLS AND SHOP EQUIPMENT

ASSESSMENT CRITERIA:

1. Check and store tools/equipment in their respective shelves/
location.

2. Post and visible corresponding labels.
3. Tools are securely logged and stored in the record book.

CONTENTS:

1. Storage and disposal of hazardous/flammable tools/materials.
2. Personal safety procedures.
3. Relevant technical information
4. Labeling procedures
5. Principles of total quality management (TQM) and 5S

CONDITIONS:

Students/trainees must be provided with the following:
1. Tool cabinet
2. Appropriate tools and equipment
3. Tool room
4. Fire extinguishers
5. Tool kit
6. Log/record book
7. Labeling materials

METHODOLOGIES:

1. Interactive lecture
2. Dual Training
3. Self- paced instruction
4. Simulation

ASSESSMENT METHODS:

1. Practical
2. Direct observation
3. Interview
4. Written examination

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 5

LO3. DISPOSE WASTE AND USED LUBRICANTS

ASSESSMENT CRITERIA:

1. Label containers for used lubricants.
2. Dispose waste/used lubricants as per workshop SOP.

CONTENTS:

1. Effects of automotive wastes to men and its environment.
2. Waste management and disposal
3. Cleaning chemicals for grease and lubricants
4. Labeling procedures and technique

CONDITIONS:

Students/trainees must be provided with the following:

1. Waste disposal area
2. Oiler
3. Handouts for waste management and disposal
4. Cleaning chemicals for grease and lubricants
5. Containers for waste and used lubricants

METHODOLOGIES:

1. Interactive lecture
2. Dual training
3. Self-paced instruction
4. Simulation
5. Demonstration

ASSESSMENT METHODS:

1. Direct observation
2. Simulation
3. Written examination
4. Interview

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 6

LO4. REPORT DAMAGED TOOLS/EQUIPMENT

ASSESSMENT CRITERIA:

1. Maintain complete inventory of tools and equipment.
2. Identify damage tools/equipment with repair recommendation.
3. Prepare report on no error/discrepancy.

CONTENTS:

1. Conducting inventory and preparing records
2. Maintenance and safe handling of tools and equipment
3. Maintenance and updating of records and reports

CONDITIONS:

1. Records and inventory of tools and equipment
2. Record books
3. Checklist
4. Waste disposal reports
5. Racks for tools

METHODOLOGIES:

1. Interactive lecture
2. Dual Training
3. Self-paced instruction
4. Simulation

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Demonstration
4. Direct observation

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 7

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE

MODULE TITLE : PERFORMING SHOP MAINTENANCE

MODULE DESCRIPTION: This unit deals with inspecting and cleaning of
work area including tools, equipment and
facilities. Storage and checking of
tools/equipment and disposal of used materials
are also incorporated in this competency.

NOMINAL DURATION : 4 hours

CERTIFICATE LEVEL : NC II

PREREQUISITE : none

SUMMARY OF LEARNING OUTCOMES:
Upon completion of this module, the trainee/student must be able to:

LO 1. Inspect and clean tools, equipment and the work area.
LO 2. Store/arrange tools and shop equipment.
LO 3. Dispose waste and used lubricants.
LO 4. Report damaged tools and equipment.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 8

LEARNING OURTCOME NO. 6.1-1

INSPECT/CLEAN TOOLS AND WORK AREA

ASSESSMENT CRITERIA:

1. Use cleaning solvent as per workshop/tools cleaning requirement
2. Check and clean work area
3. Wipe and dry wet surface/spot in work area

CONTENTS:

1. Workshop policies.
2. Types and usage of cleaning chemicals.
3. Safe handling of equipment and tools.
4. Service procedures.
5. Equipment maintenance standards.

CONDITIONS:

Students/trainees must be provided with the following:
1. Open workshop/garage
2. Well ventilated enclosed work and office area
3. Wash area and mess hall
4. Cleaning chemicals
5. Inventory of equipment and tools
6. Rugs
7. Containers for used oils
8. Vehicle
9. Oiler

METHODOLOGIES:

1. Lecture
2. Demonstration
3. Self-paced instruction
4. Dual Training

ASSESSMENT METHODS:

1. Direct Observation
2. Practical
3. Interview
4. Written examination

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 9

LEARNING OUTCOME 2.1
PREPARE THE VEHICLE FOR DRIVING

Learning Activities Special Instructions
Compare your answers with the
 Read Information sheet answer key
on 6.1-1 Use cleaning
solvent as per Evaluate your own work using the
workshop/tools cleaning Performance criteria
requirement Present your work to your trainer for
evaluation
 Answer self-check on
6.1-1 Use cleaning Keep a copy of your work for the
solvent as per next activities
workshop/tools cleaning
requirement

 Compare answer with Compare your answers with the
Answer self-check on answer key.
6.1-1 Use cleaning Evaluate your own work using the
solvent as per Performance criteria
workshop/tools cleaning
requirement Present your work to your trainer for
evaluation

 Read Information sheet Keep a copy of your work for the next
on 6.1-2 on Check and activities
clean work area

 Answer self-check on
6.1-2 on Check and
clean work area


 Compare answer with

Answer self-check on
6.1-2 on Check and
clean work area

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 10

Information Sheet LO 6.1

Inspect/ clean tools and shop equipment

LEARNING OBJECTIVES: AFTER READING THIS INFORMATION

SHEET THE TRAINEES MUST BE ABLE TO.

1. Tools, equipment and work area is inspected and cleaned, free from
dust, grease and other substances

2. Cleaning solvent used as per workshop cleaning requirements is
observed.

3. Work area is checked and cleaned.
4. Wet surface or spot in the work area is kept dry.

KEY POINTS:

 Housekeeping can help prevent injuries and improve productivity.
 Every worker should play a role in housekeeping, even if that means

keeping his or her own workspace clean.
 Housekeeping, should be an ongoing process, not a onetime practice.

 BASICS OF SHOP SAFETY
 Safety in the shop

 Safety means protecting yourself and others from

possible danger and injury. You do not want to hurt yourself or

someone else. To prevent this follow the safety rules in the shop.

When everyone obeys the rules, the shop is a much safer place in

which to work than your home!

 Safety is your job in the shop you are “safe” when you protect your

eyes, fingers, feet all of you from danger. Just as importantly, you

must look out for the safety of others around you.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 11

 SHOP LAYOUT

The term shop lay out means the location of workbenches, vehicle lifts,
machine tools, and other equipment shop layouts vary. When you first go
into a shop, find where everything is located. Many shops have lines painted
on the floor to mark off work areas. This lines guide customers and workers
away from danger zones around equipment. The lines also remind workers
to keep their tools and equipment inside

Signs posted around machinery and on the walls remind everyone to operate
the machinery safety. Many of these are OSHA signs. OSHA stands for
Occupational safety and health administration. This federal agency is
responsible for studying and correcting conditions and equipment that may
be hazardous to workers. Always follow the posted instructions. The most
common cause of accidents in the shop is failure to follow instructions.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 12

CLEANING SOLVENT, THINNERS USED AS PER WORKSHOP CLEANING
REQUIREMENTS.

ACETONE- Acetone is a residue free, solvent thinner and

cleaner. Due to quick evaporation, its perfect for projects needing fast drying

times. Acetone is very effective as a thinner, cleaning solvent, or remover for

fiber glass resins, polyester and epoxy resins, adhesives or contact cement,

ink, latex paint, and uncured lacquers. It is also excellent at degreasing

metal work.

cement, ink, latex paint, and uncured lacquers. It is also excellent at
degreasing metal work.

LACQURE THINNER-

Lacquer thinner is a high solvency medium drying time, formulated solvent
effective as a thinner and cleaner for lacquer and epoxy coating. It’s a great
choice for when durable attractive finish is desired whether on wood or
metal, sprayed or brushes, tools, and equipment immediately after use.

MINERAL SPIRITS- This general- purpose solvent is effective at

thinning oil based paints, varnishes, stains, and polyurethanes. Mineral

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 13

spirits leave behind no residue. It is best as a cleaner on brushes, tools, and
equipment while paints or other substances are still wet.

ODORLESS MINERAL SPIRITS- Safe from harmful

fumes, odorless mineral spirits is a low- odor highly refined solvent formula

effective in oil based paints, stains and varnishes as a thinner and blending

solvent that dries with minimal residue. Odorless mineral spirits dissolves

and removed grease, grime, and oil from most surfaces and can be used to

clean brushes and equipment and tools.

LIST OF CHEMICALS.

 Acetone
 Brake wash blend
 Lacquer thinner
 Methyl ethyl ketone
 Mineral spirits
 Odorless mineral spirits
 Toluene
 VM&P Naphtha
 Xylene

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 14

PREVENT SLIPS, TRIPS AND FALLS.

Slips, trips and falls were the second leading cause of nonfatal occupational
injuries or illness involving days away from work. According to data from
BUREAU OF LABOR STATISTICS.

OSHA’S Walking- working surfaces standard states that all workplaces
should be ‘kept clean and orderly and in a sanitary condition’. The rule
includes passageways, store rooms and service rooms. Floors should be
clean and dry. Drainage should be present where “wet processes are used”

“ Things like oils and grease- if you don’t use the right kind of cleaning
protocols, you’ll just spread slipperiness around rather than getting it up
and off the floor”

To help prevent slip, trip and fall incidents the Canadian center for
occupational health and safety recommends the following.

 Report and clean up spills and leaks.
 Keep aisles and exits clear of items.
 Consider installing mirrors and warning signs to help with blind

spots.
 Replace worn, ripped or damage flooring.
 Consider installing anti-slip flooring in areas that cant always be

cleaned.
 Use drip pans and guards.

In additional, provide mats, platforms, false floors or other dry standing
places where useful according to OSHA. Every workplace should be free of
projecting nails, splinters, holes and loose boards. The employers should
audit for trip hazards, and encourage workers to focus on the task at hand.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 15

SELF CHECK LO 1:

READ THE INSTUCTION CAREFULLY; the answers are provided for
each of the following questions. Select the best answer.
1. Give at least 5 chemical cleaning solvent
2. Means protecting yourself and others from possible danger and

injury?
a. Your self
b. Everyone
c. Safety
3. Posted around machinery and on the walls remind everyone to
operate the machinery safety?
a. 5’s
b. OSHA
c. Signs
4. To help prevent slip, trip and fall incidents the Canadian center for
occupational health and safety recommends give at least 5?
5. ----- means the location of workbenches, vehicle lifts, machine
tools, and other equipment?
a. Shop lay out
b. Workshop
c. Machine shop

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 16

ANSWER KEY LO.1

1. Acetone
Lacquer thinner
Methyl ethyl ketone
Mineral spirits
Odorless mineral spirits

2. C
3. C
4. Report and clean up spills and leaks.

Keep aisles and exits clear of items.
Consider installing mirrors and warning signs to help with
blind spots.
Replace worn, ripped or damage flooring.
Consider installing anti-slip flooring in areas that cant
always be cleaned.
Use drip pans and guards.
5. A

REFERENCES:

https://cse.google.com/cse?q=BODY+BODY+SYSTEM+IN+AUTOMOTIV
E+WORK&sa=Search&ie=UTF-8&cx=partner-
pub%2D3317167162609756%3A3134777453#%

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 17

Information Sheet LO 6.2

Store/ arrange tools and shop equipment

LEARNING OBJECTIVES: AFTER READING THIS INFORMATION SHEET

THE TRAINEES MUST BE ABLE TO.

1. Tools and equipment are arranged and stored in their respective
shelves/ location.

2. Corresponding labels are posted and visible.
3. Tools are secured and logged in record book

KEY POINTS:

 Housekeeping can help prevent injuries and improve productivity.
 Every worker should play a role in housekeeping, even if that means

keeping his or her own workspace clean.
 Housekeeping, should be an ongoing process, not a onetime practice.

What Is the 5S System?

The 5S system is a lean manufacturing tool that improves workplace
efficiency and eliminates waste. There are five steps in the system, each
starting with the letter S:

1. Sort 2. Set In 3. Shine 4. 5. Sustain
Order Standardize

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 18

By providing a systematic framework for organization and cleanliness, 5S
helps facilities avoid lost productivity from delayed work or unplanned
downtime.

The Steps of 5S

5S was created in Japan, and the original “S” terms were in Japanese, so
English translations for each of the five steps may vary. The basic ideas and
the connections between them are easy to understand, though.

Step Name Japanese term Explanation
Seiri (tidiness) Remove unnecessary items from each
1. Sort area
Seiton (orderliness) Organize and identify storage for
2. Set In Seiso (cleanliness) efficient use
Order Seiketsu Clean and inspect each area regularly
3. Shine (standardization) Incorporate 5S into standard operating
4. Shitsuke (discipline) procedures
Standardize Assign responsibility, track progress,
and continue the cycle
5. Sustain

These steps feed into each other, so the sequence is important.

Clearing out unnecessary materials in step 1 (Sort) will provide the space
needed to organize the important items in step 2 (Set In Order).

Then, once the work space is de-cluttered and organized, dirt and grime can
be removed in step 3 (Shine).

These changes to workers’ job duties and work environment should be
reflected in updated procedures through step 4 (Standardize).

Finally, those new procedures won’t amount to much unless responsibility
is assigned and progress is tracked — as required for step 5 (Sustain). And
with responsibility and tracking, workers will continue to apply the steps,
returning to step 1.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 19

Step 1: Sort

The first step in the 5S process is Sort, or “seiri,” which translates to
“tidiness.” The goal of the Sort step is to eliminate clutter and clear up space
by removing things that don’t belong in the area.

Clearing the Work Area

For this step, take a close look at the items, tools, and materials in a work
area. Items that are necessary or useful for the work being done in that
space should be kept there. Everything else should be removed.

Some of those removed items will need to be thrown away or recycled. Other
items might belong to another work process or location; they should be
returned to their “homes.” However, you might find some items that you
aren’t sure about.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 20

Red-Tagging Unknown Items

If you find an item that you can’t identify, or that has uncertain ownership,
it’s time to use a red tag. “Red-Tagging” temporarily attaches a highly-visible

tag to the item, which notes where it was found and when. Then, red-tagged
items from all work areas are collected in a single location: a “lost and

found” for tools, materials, and equipment.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 21

If a work area is missing an important
tool, check the red tag collection area to see if it was found somewhere else.
Supervisors for each work space should check the red tag collection area
periodically, in case something has been missed. Anything that belongs in a
work space should be taken back there.

Reassigning Tagged Items

Items may wait in the red tag collection area for a long time. In that case,
the original work area (where that item came from) doesn’t seem to need it
anymore. It may be useful elsewhere, though.

In one common approach, items may be left in the red tag collection space
for thirty days. After that, any supervisor may claim the item for their own
work area. If nobody wants it after another week, the item can be removed
from the facility entirely. Sell it, recycle it, or throw it away.

If an item will definitely be needed by the company, but isn’t needed right
now, it might be best to store it for later. Before putting anything into
storage, be sure it will actually be needed again. Have a specific plan for
getting that item out of storage again, at a specific time. Don’t store things
“just in case” without good cause, and keep track of what’s been stored.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 22

Step 2: Set In Order

The second step, Set In Order, was originally called “seiton,” which
translates to “orderliness.” A variety of names have been used in English:
“Systematic Organization,” “Straightening Out,” and “Simplify,” for example.
No matter what it’s called, the goal of this step is to organize the work area.
Each item should be easy to find, use, and return: a place for everything,
and everything in its place.

Building a 5S Map

Tools that are used frequently should be stored near the place they are
used. Spare equipment, supplies, and other tools that are used less often
can be kept in a central location, where multiple teams can share them.
Items that are typically used together (such as drills and drill bits) should be
stored near each other. Each of these decisions will make sense on its own,
but it may become difficult to keep track of everything. It may be helpful to
create a 5S map as part of this process.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 23

A 5S map is a diagram or floor plan that provides an overview of a work
area, process, or station. It provides a visual reference to show where the
tools, supplies, workers, and travel paths are, and how they relate to each
other. A good map may also include a description of the work that happens
in the area shown.

Depending on your facility’s needs,
you may find one approach easier than another:

 Draw up a map, and then implement it
 Physically arrange the workplace first, and then map it out
 Map as you go, testing ideas and writing down what works well

No matter which approach is used to create it, the resulting 5S map should
be kept as a training tool, used for reference in later steps of 5S, and
updated over time as the work area changes.

Communicating the Plan

Once storage locations are assigned, each storage area should be labeled.
Label the outside of cabinet doors to help workers quickly identify what’s
inside each one. Then, label any interior shelves to show where different
supplies belong. The same ideas extend to rack labels, bins, and other
storage systems.

CBLM Date Developed: Document No. DRV-PTC-32-
Driving NC II March 2018 002-20
Date Revised: Issued by:
Performing Shop June 2020
Maintenance Developed by: TESDA,PTC-
Kalinga
LEA LIBERTY A.
WANGAG Revision # 01 P a g e | 24

Many facilities use a “shadow board” for tool storage, to ensure that each
tool is easy to put back in its correct storage place. With this approach, a
label matching the shape and size of the tool is placed where that tool
belongs. Workers can immediately spot where each item belongs, and know
at a glance if the item is there or not. No more time wasted looking through
drawers and bins.
Organization can extend to the floor, too. Work areas, movement lanes, and
storage for supplies and finished products can all be marked with floor
marking tape.
5s System Best Practices Guide
The free 5s guide will get you started on the path to efficiency.

Step 3: Shine

The third step of 5S is Shine, or “seiso,” which means “cleanliness.” While
the first and second steps cleared up space and arranged the area for
efficiency, this step attacks the dirt and grime that inevitably builds up
underneath the clutter, and works to keep it from coming back.

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Routine Cleaning

Shine moves far beyond just pushing a broom around every now and then.
It involves regular cleaning of every part of the work area — often a daily
wipe-down, and a more thorough cleaning each week.

Importantly, the Shine step is not meant to be a job for the maintenance or
janitorial staff. Each worker should clean their own work area, and the
equipment they use. This approach has several benefits:

 Workers who are familiar with the area will quickly notice any
problems that arise

 Hazards or difficult situations will be understood and accounted for
 Items that are out of place or missing will be recognized
 Workers will tend to keep their own workspaces cleaner during normal

operations

Everyone should pay attention to the overall cleanliness of the workplace,
being willing to pick up trash and so on. But for 5S to give the best results,
each worker should take personal responsibility for their own working

space.

Shine as Preventative Maintenance

Keeping work areas clean will have many advantages. One important
advantage is that it’s easy to spot leaks, cracks, or misalignments. If the

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people keeping the area clean are the same people who work there regularly,
they will be quick to recognize any of these problems.
Leaving those problems unnoticed and unresolved could result in equipment
failure, safety hazards, and loss of productivity. With the constant cleaning
and inspections used in the Shine step of 5S, the system can feed into a
preventative maintenance program. This way, 5S can extend the working life
of equipment and help reduce emergency downtime.

Step 4: Standardize

The first three steps of 5S cover the basics of clearing, organizing, and
cleaning a work space; on their own, those steps will provide short-term
benefits. The fourth step is Standardize, or “seiketsu,” which simply means
standardization. By writing down what is being done, where, and by whom,
you can incorporate the new practices into normal work procedure. This
paves the way for long-term change.
The Power of Writing Things Down

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It’s been said that “If it isn’t written down, it didn’t happen.” Writing down
the decisions that you make in your 5S program will help ensure that your
work doesn’t just disappear. If you made a 5S map in the Set In Order step,
that map can be part of your new standard for the area. In the same way,
the process that you use for red-tagging items can be written down and
included in the standards.

Writing out your decisions doesn’t mean you can’t change your mind,
though. The purpose of 5S is to make your workplace better, not to make it
unchangeable. You are writing the standards for your facility, and you can
change them to fit new information or new business needs.

Tools for Standardizing

Once you’ve made decisions on how to change your work practices, those
decisions need to be communicated to workers. This communication is a key
part of the Standardize step. Common tools for this process include:

 5S checklists – Listing the individual steps of a process makes it easy
for workers to follow that process completely. It also provides a simple
auditing tool to check progress later on.

 Job cycle charts – Identify each task to be performed in a work area,
and decide on a schedule or frequency for each of those tasks. Then,
assign responsibility to a particular worker (or job duty). The resulting
chart can be posted visibly to resolve questions and promote
accountability.

 Procedure labels and signs – Provide operating instructions, cleaning
steps, and preventative maintenance procedures right where that
information will be needed.

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Step 5: Sustain

The fifth step of a 5S program is Sustain, or “shit sue,” which literally means
“discipline.” The idea here is continuing commitment. It’s important to follow
through on the decisions that you’ve made — and continually return to the
earlier steps of 5S, in an ongoing cycle.

Never “Once and Done”

The 5S approach was never meant to be a one-time event, but an ongoing
cycle. This is key, because early successes in 5S can open the way for
problems. If open space becomes available in the Sort step, but afterward,
tools and materials are allowed to gradually fill in that space without any
organization, the end result can be an even bigger mess. The solution is to
apply the ideas of 5S over and over, as a routine part of normal work. That’s
why Sustain is so important.

Sustaining a 5S program can mean different things in different workplaces,
but there are some elements that are common in successful programs.

 Management support – Without visible
commitment from managers, the 5S processes
won’t stick around. Supervisors and managers
should be involved in auditing the 5S work
processes, and getting feedback from workers.
They also need to provide the tools, training, and
time for workers to get their jobs done right.

 Department tours – Bringing teams from one
department to visit other departments will help
familiarize the entire workforce with the processes
of your facility. This type of “cross pollination”
helps to spread good ideas, and inspires people to
come up with new ways to improve the 5S
implementation.

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 Updated training – As time passes, there may be
changes in your workplace, such as new
equipment, new products, or new work rules.
When this happens, revise your 5S work
standards to accommodate those changes, and
provide training on the new standards.

 Progress audits – The standards that are created
in the 5S program should provide specific and
measurable goals. Checking on those goals with a
periodic audit can provide important information
and guidance. Where is 5S working well? Where
are teams falling behind?

 Performance evaluations – Once you know your
goals are reasonable, make performance part of
each employee evaluation. When teams and
individuals perform well, celebrate it, and post
overall results so each team can see how they
compare to the rest of the facility.

Sustain Is Not the End of 5S

While it’s the last step in the sequence, Sustain is not the end of 5S as a
whole. One pass through the steps can expose problems that were hidden
beforehand. Following the steps again can resolve those problems, and help
discover new ways to improve. Continue through the cycle again and again
to keep your facility at the top of its potential.

A Sixth “S” for Safety

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When it comes to lean manufacturing and workplace improvement, 5S is
one of the most widely known and used lean tools. It’s no surprise: 5S can
increase workplace efficiency, reduce costs, and improve quality. But with
many lean programs, it’s easy to focus only on those goals, and lose sight of
the human factor. Worker safety is critical. That’s why many facilities add
another step to the 5S cycle, calling the result “6S” — with Safety.

Unlike the first five steps, Safety is not a sequential step. It must be
considered during each of the other steps. During the Sort phase, for
example, you might decide that a given tool is obsolete because a newer
version is safer to use. Likewise, during the Standardize step, work
procedures need to be standardized to improve workplace safety, not just
efficiency.

Keeping workers safe isn’t just the right thing to do: there is a hefty
monetary cost for accidental workplace injuries. A study by Stanford
University found that the costs for a bone fracture can cost a company
$50,000 up front, as well as another $55,000 in indirect costs. Each
incident can lead to an OSHA inspection and citations, as well as an
increase in insurance costs.

Benefits of a 5S Program

Because 5S focuses on improving a workplace, and different workplaces may
have little in common, it can be hard to predict the exact results of using the
program. However, some benefits are almost always found:

 Better time usage - Getting rid of unwanted
materials and organizing the important tools and
supplies will eliminate clutter and confusion.
Workers spend less time finding and retrieving
what they need, and can be more productive
instead.

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 Less wasted space – Eliminating unnecessary
material stockpiles and consolidating tool storage
will clear up room for more useful applications.
Every square foot of floor space has a cost, and
getting the most out of that investment will
maximize your facility’s profitability.

 Reduced injury rates – Organizing work areas for
efficiency and ease of use will reduce the
movements needed for workers to do their jobs.
Removing clutter and routinely cleaning up spills
will eliminate trip hazards. As a result, workers
will experience less fatigue and fewer injuries.

 Reduced equipment downtime – When tools and
equipment are kept clean, routinely inspected, and
used in a standardized way, preventative
maintenance is much easier, and major failures
can often be prevented entirely.

1. Improved consistency and quality –
Standardizing work processes will reduce

variations and mistakes. By eliminating faults and
failures, overall productivity can be dramatically
improved.

 Heightened employee morale – When 5S
principles are used effectively, workers see that
their input is valued, and their performance is
recognized. This creates an environment where
workers can feel pride in their work, and take an
interest in improving their company.

These benefits are not just good feelings. By documenting their situations
before and after adopting 5S, many facilities have been able to show actual,
measured improvements.

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REFERENCES

https://www.graphicproducts.com/articles/what-is-5s/

https://cse.google.com/cse?q=BODY+BODY+SYSTEM+IN+AUTOMOTIVE+W
ORK&sa=Search&ie=UTF-8&cx=partner-
pub%2D3317167162609756%3A3134777453#%9C

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SELF- CHECK LO2

READ THE INSTUCTION CAREFULLY; The answers are provided for each of the
following questions. Select the best answer.

1. To eliminate clutter and clear up space by removing things that don’t belong
in the area.

a. Sort
b. Set in order
c. Shine
d. Standardize

2. This step attacks the dirt and grime that inevitably builds up underneath the clutter,
and works to keep it from coming back.
a. Set in order
b. Shine
c. Standardize
d. Sort

3. Which literally means “discipline.”
a. Shine
b. Sustain
c. Sort
d. Safety

4. By writing down what is being done, where, and by whom, you can incorporate the
new practices into normal work procedure. This paves the way for long-term change.
a. Safety
b. Sustain
c. Standardize
d. Sort

5. Was originally called “seiton,” which translates to “orderliness.”
a. Standardize
b. Sort
c. Safety
d. Set in order

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ANSWER KEY LO 6

1. A
2. B
3. B
4. C
5. D

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Information Sheet LO 6.3

Dispose waste/ used lubricant

LEARNING OBJECTIVES: AFTER READING THIS INFORMATION SHEET

THE TRAINEES MUST BE ABLE TO.

1. Waste and used lubricants are disposed in accordance with the
standard operational procedures and environment regulations.

2. Containers for waste and used lubricants are properly labeled.
3. Personal safety in disposing waste and used lubricants is evident.

KEY POINTS:

 Housekeeping can help prevent injuries and improve productivity.
 Every worker should play a role in housekeeping, even if that means

keeping his or her own workspace clean.
 Housekeeping, should be an on going process, not a one time practice.

What types of hazards do we look for in a workplace?

Types of workplace hazards include:

 Safety hazards such as those caused by inadequate machine guards, unsafe
workplace conditions, unsafe work practices.

 Biological hazards caused by organisms such as viruses, bacteria, fungi and
parasites.

 Chemical hazards caused by a solid, liquid, vapour, gas, dust, fume or mist.
 Ergonomic hazards caused by physiological and psychological demands on

the worker, such as repetitive and forceful movements, awkward postures
arising from improper work methods, and improperly designed workstations,
tools, and equipment.
 Physical hazards caused by noise, vibration, energy, weather, heat, cold,
electricity, radiation and pressure.
 Psychosocial hazards that can affect mental health or well-being such as
overwork, stress, bullying, or violence.

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Tag out- A tag on its own is not an effective isolation

device. A tag acts only as a means of providing information to others at the

workplace. A lock should be used as an isolation device, and can be

accompanied by a tag.

HAZARDOUS MATERIALS.

A hazardous materials is anything corrosive, explosive, flammable,
radioactive, reactive, or toxic (poisonous). These materials may endanger

human health or pollute the environment if improper handled. Many
materials used in automotive service can be hazardous if not handled

properly. Examples include air conditioning refrigerant, anti-freeze, brake
fluid, gasoline, and engine oil. Other hazardous materials are asbestos dust,

parts cleaning solvent, grease, paint and shop adhesive (glue and cement).

To protect workers from unsafe exposure to hazardous materials on the job.
OSHA issued the hazard community standard. This is often called the right
to know” law. It requires the shop owners to inform people who work there
of the risks. The worker must receive information and training on how to

protect themselves. The shop must also maintain a file of material safety
data sheets in a place that is accessible to all employees. Many types of
automotive service work create hazardous waste. This is any materials that
could pose danger to human health and the environment after it is
discarded. Some hazardous waste, such as dirty solvent, is recycled. This
means it is treated and used again. Both the environmental protection
agency(EPA) and OSHA have rules covering the labelling and disposal of
hazardous waste. Some states and local governments have even stricter
rules.

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Non-mechanical hazards
Non-mechanical hazards associated with machinery and equipment can
include harmful emissions, contained fluids or gas under pressure,
chemicals and chemical by-products, electricity and noise, all of which can
cause serious injury if not adequately controlled. In some cases, people
exposed to these hazards may not show signs of injury or illness for years.
Where people are at risk of injury due to harmful emissions from machinery
and equipment, the emissions should be controlled at their source.

HOW TO PROPERLY RECYCLE AND DISPOSE OF AUTOMOTIVE
CHEMICALS

Professional mechanics and businesses that deal with fixing cars are held to
strictest of rules concerning disposal and recycling of automotive materials.
These rules apply whether the business just changes automotive oil or only
sells tires. In fact automobiles are one of the most recycled consumer goods
on the planet, fluids, metals, plastics and other part of the modern
automobile is salvaged and reused- sometimes even for another car or truck.
The responsibility to recycle used oil, coolant and other products of driveway
car maintenance or repair is sole responsibility of the shade tree mechanic.

HOW TO DISPOSE CHEMICAL PRODUCT? FOLLOW THESE SIMPLE
GUIDELINES;

 Keep each fluid separate and in a dedicated, sealed container until it
can be either recycled or disposed of

 Consult local, state and federal regulations regarding disposal of fluid.
 Contact your local waste management company for drop-off and

recycling locations.

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 Never dispose of any automotive fluids by dumping them on the
ground, into a storm drain or into a septic system

 Responsible disposal and recycling of engine oil, coolant or other
automotive fluids is just as important as regular car maintenance

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The safety in disposing waste

Principles

Proper waste disposal begins with good waste management by the
researcher, including minimum waste generation, reusing surplus

materials, and recycling of appropriate (i.e., uncontaminated) waste. The
generated waste must be properly collected and stored, paying close

attention to labeling, segregating according to chemical compatibility, and
accumulating in a well-ventilated location. This location should be well
labeled. Other laboratory waste items such as sharps and glass must also

be disposed of with care in appropriately labeled and compatible containers.

Procedure

1. Waste Management

1. Users should make an effort to keep waste to a minimum. The best

way to do so is by reducing the scale of operation, which minimizes
the quantity of waste generated. Whenever possible, chemicals used
should be substituted with less hazardous chemicals.

2. Chemical quantities should be kept to a minimum. Store only what
will be used in the near term.

3. Besides preventing or minimizing waste generation, chemicals should
be recycled or recovered for reuse.

4. When waste is generated, it must be disposed of properly. Sink
disposal may not always be appropriate and may end contaminating
drinking water. Alternative methods of disposal should be considered

including incineration, treatment, and land disposal. The institute's
EHS office should be consulted to determine the proper disposal

method for different waste types.

2. Waste Collection and Storage

1. When generating or managing any chemical waste, appropriate
personal protective equipment (PPE) must be worn, and engineering
controls should be implemented as necessary.

2. Collect and store chemical waste at or near the point of generation in
a designated satellite accumulation area. This accumulation area
should be well marked for easy identification.

3. Chemical waste must be stored in compatible containers with closed
and properly fitted caps.

4. Waste containers must be labeled mentioning chemical compositions,
the accumulation start date, and hazard warnings as appropriate. The
institute's EHS office typically provides these required labels.

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5. Incompatible waste types should not be mixed and should be kept
separate in order to avoid any reaction, heat generation, and/or gas
evolution.

6. Waste containers should be stored in secondary containers in a
ventilated, cool, and dry area.

7. In the central accumulation area, waste containers should be
grounded to avoid fire and explosion hazards.

8. Trained laboratory researchers who are most familiar with the waste
generated should work with EHS to ensure proper waste management.

3. Sharps Disposal - Syringes and Needles

1. Chemically contaminated needles, syringes, and razor blades should
be disposed of inside a proper sharps container.

2. Syringes or needles must never be disposed of in a laboratory waste
bin or a general waste container.

4. Glass Recycling

1. Recycling glass is friendly to the environment as it reduces pollution
caused by the waste ending up in landfill sites. Every laboratory
should have a separate recycling bin dedicated to glass.

2. Clean empty glass bottles and broken glassware may be recycled. To
clean an empty glass bottle, it must be "triple rinsed" with water or
another suitable solvent and air-dried before disposal.

3. Chemically contaminated laboratory glassware such as sample tubes,
droppers, and glass wool must be disposed of as controlled waste.

Applications and Summary

In this document, a basic guideline for laboratory waste disposal is provided.
Users must work and comply with their institute's EHS office to determine
the proper method for waste disposal satisfying diverse regulations and
standards. The laboratory user should be cognizant of what waste material
is being generated and hazards present should be carefully assessed to
determine proper waste disposal, which may otherwise put public health or
the environment in danger. No matter how small or large a waste quantity is
handled, proper PPE must be worn.

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REFERENCES;
https://www.hsedot.com/2019/05/what-is-mechanical-and-non-mechanical.html
https://birddogtrafficcontrol.com/blog/most-common-road-signs-you-should-be-
aware-of/

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