How 5S QE will improve : ü Productivity : Reduce waiting time ü Quality : Reduce making reject item ü Delivery : Reduce waiting time or turnaround time ü Cost : Reduce unnecessary rework/repair ü Safety : Arrangement of items eliminates risk to slip, trip and fall ü Morale : Creating conducive working environment , smooth operation, happy customer, happy workers, less MC (less sickness) ü Innovation : Application of Continuous Improvement (new ideas)
What How Kaizen Activities Reducing Waiting Time Reduce tank truck driver waiting time, movements -reduce 100 steps to 50 steps One Stop Point for Driver registration, Pass collection, HP surrender/collection, DT & LI collection Reducing making defect item Introduce simpler process/easy process Reducing unnecessary rework Improvise workers activity for water draining, -eliminate product spillage for before and after shipment and monthly (5 times/month) Enlarge sum at TK 8,9 and 12 for ADO water draining activity Improve working environment Improvise emergency equipment. PPE arrangement in PPE & Fire Fighting Room Reducing hazards to driver or workers at truck ingress area 1. Arrangement of PPE according to ERT body size (S, M, L to XL) and by name/photo 2. Equipment arrangement by requirement/size Improve working environment Reduce employee stress from smooth operationArrangement of files/equipment close to workers based on usage frequency 1. Filing arrangements in dispatcher room 2. DT and seal arrangement based on FIFO Innovation New ideas will be generated from time to time 1. Verities of Kaizens emerged
5S Promotion & Motivation 5 locations Employee rest area Pantry Fire wall Near to Surau 5S polo shirt for Committees 2020-2021 2022-2023 Daily 5 minutes 5S at 10 am + 6 monthly major 5S 3 locations 5S polo shirt for Committees
5S Promotion & Motivation
BLT 5S Assessment Checklist by Zones (Audit Form), Scoring Results & Dimension POOR FAIR AVERAGE GOOD EXCELLENCE
56 WEEKLY & MONTHLY QUARTERLY TWICE YEARLY MFCA,MNJ,MFFN MFCA,MNJ, MFFN 12. 5S Assessment Schedule 2022 Team Assessment & Assessment Schedule
Q1 2022 Internal Assessment Results 84.4% 91% 93.2% 90.9% 93.7% 92% Q2 2022 Q3 2022 Q4 2022 89.3% 88.5% 90.2% 88.9% 89.5% 92.7% 88.0% 92% 87.0% 86.5% 85.0% 89.0% 90.0% 87.0% 86.0% 85.0% 93.0% 91.0%
2022 Internal Assessment INTERNAL ASSESSMENT 1H 2022 INTERNAL ASSESSMENT 2H 2022 80.2% 86.1% 86.8% 76.0% 88.5% 88.8% 90.0% 88.2% 80.2% 84.5% 85.5% 86.2%
5S REWARDS (ZONE 1) No Activities 1 Built designated place for daily toolbox talk meeting 2 Put main entrance signage for visitor information 3 Provide new DT & Seal spaces for storage- Improve searching time 4 Wall painting activity at main office building 5 Install convex mirror at the entrance to staff/visitor car park area 6 Add switch at exit door (Entrance gate) 7 Put signage ‘Sila Semak Kompartmen” at seal inspection ladder 8 Put “keep your distance” signage on the chair in main conference room
5S REWARDS (ZONE 2) No Activities 1 Provide new ramp at jetty platform for hose laying activity 2 Apply wordings on hose ramp “Caution Slippery Surface” 3 Reorganize tools inside garden rack 4 Paint garden’s walking entrance 5 Garden’s red & blue stone decoration 6 Relocate trees at the emergency response area access to garden
5S REWARDS (ZONE 5) No Activities 1 Maintaining level of grass at tank farm area 2 Repaint all faded pipelines , staircase and others
5S REWARDS (ZONE 6) No Activities 1 Add new demarcation line for tank truck positioning in loading bay 2 Indicate top & bottom before entering loading bay 4 3 Relocate light at loading bay 4 4 Reposition barrier in front of new firefighting shed 5 Numbering for drip pan at each loading bay 6 Numbering for tire choke (no 1),drip tray (no 2) , civacon (no 3) & vapor hose (no 4)
Criteria 4 : IMPLEMENTATIONS CREATIVE & INNOVATIVE IDEAS
Sort / Major 5S Activities in 2022
Before After Location: Main Office Wall Description: Empty wall at main office building Description: Huge safety mural at main office wall Benefit: Promote safety culture to the public ZONE 1-Safety
Before After Location: Truck driver toilet Description: Utilize fresh water for toilet bowl usage Description: Installing hand basin on top - outlet pipe connecting to toilet bowl water tank Benefit: Reducing freshwater consumption – estimate 200 liters/month Zone : 3 (Green Toilet)
Before After Location: Description: Under utilize empty area/fire wall Description: Creating a multipurpose rest area for truck drivers , recycling of empty additive drums Benefit: Providing an area for driving to rest at the same providing continuous awareness on SSHE knowledge 2018 2019 2022 Zone : 1 (Driver Rest Area)
• Additive empty drums recycling-used at tank truck driver Rest Area
Before After Location: BLT Main Entrance Description: Old signboard at main entrance Description: Replaced with new acrylic signboard at main entrance Benefit: Nice view and give good impression to all workers, visitors and customers. ZONE 1-Morale
Before After Location: Garden Description: The soil condition is barren Description: Planting more grasses & flowers Benefit: Create “Go Green” environment inside terminal area & providing staff with health therapy (reflexology stones) Transforming BLT Garden 2019 2020- 2021 2022
Before After Location: Toilet (Operation Site Area) Description: The toilet at operation site Description: Repaint the toilet at operation site area with green color Benefit: Provide nice view and create “Go Green” environment inside terminal area Zone : 3 (Green Toilet)
Before After Location: Toilet (Operation Site Area) Description: The toilet at operation site in bad condition Description: Renovate the toilet at operation site area Benefit: Provide hygiene & comfortable toilet facility to our customers & staffs (Drivers, employees, contract workers, contractors & visitors.) ZONE 3-Morale
ZONE 3-Morale Before After Location: Truck driver toilet Description: Utilize fresh water for toilet bowl usage Description: Rainwater harvesting, utilize rainwater for toilet bowl usage. Installed meter (Nov 2022 to monitor usage) Benefit: Reducing freshwater consumption – estimate 200 liters/month Zone : 3 (Green Toilet)
ZONE 3-Morale Before After Location: Truck driver toilet Description: Utilize fresh water for toilet bowl usage Description: Installing hand basin on top - outlet pipe connecting to toilet bowl water tank Benefit: Reducing freshwater consumption – estimate 200 liters/month Zone : 3 (Green Toilet)
Before After Location: Loading Bays Description: Faded fascia board at loading bays. Description: Repainted fascia board with Petron red strap Benefit: Provide nice view and environment inside terminal parameter. ZONE 6-Morale
Before After Location: Wild Trees Outside Terminal Fencing Description: Wild trees outside terminal fencing Description: Removed wild trees outside terminal fencing Benefit: Eliminate biological hazard around terminal fencing ZONE 2-Safety
Before After Nil Location: Prayer Room (Surau) Description: Old prayer room (Surau) Description: Renovate new prayer room (Surau) Benefit: Provide comfortable place of worship for Muslims (Drivers, staffs, contractors, contract workers, security guards & visitors) ZONE 4-Morale
Before After Location: Car Park Description: No yellow line for cark park Description: Yellow lines for cark park Benefit: Dedicated parking space for staffs & visitors, preventing property damage ZONE 1-Safety
Before After Location: Car Park Description: Car park with no signage Description: Placed proper signage at car park Benefit: Dedicated space for staffs & visitors with proper signage ZONE 1-Safety
Before After Location: Safety Scoreboard Description: Faded safety scoreboard Description: Replaced new safety scoreboard with small LPS garden. Benefit: Clear visibility on the safety performance statistic. Nice view and give good impression to all workers, visitors and customers. Keep remind the workers & drivers on LPS tools. ZONE 1-Safety
Before After Location: Schedule Wastes Description: Concrete floor Description: Epoxy floor coating Benefit: Epoxy floor coating makes renders concrete exceptionally durable. Protects the underlying concrete from moisture, stains, grease and cracks. ZONE 3-Environment
Before After Location: Warning Signboard (Private Property) Description: Faded warning signboard (Private Property) Description: Replaced warning signboard (Private Property) Benefit: Provide clear visibility on the warning signboard to the public All Area-Security
Before After Nil Location: Parking Signage Description: Nil Description: New parking signage for staffs & visitors Benefit: Provide clear direction to car park area for staffs & visitors ZONE 1-Security
Before After Location: Office Building (Near Main Entrance) Description: Unpainted concrete structure Description: Painted concreted structure Benefit: Nice view and give good impression to all workers, visitors and customers. ZONE 1-Quality
Before After Location: Main Entrance Gate Description: Corroded metal gate structure and concrete wall Description: Repaint corroded metal gate structure and concrete wall Benefit: Ensuring the facilities conditions do not deteriorate against times ZONE 1-Cost saving
Before After Location: Mini Warehouse Description: Improper equipment arrangement inside mini warehouse Description: Equipment sorted properly based on size and types Benefit: Better space arrangement (eliminates hazards and reduce searching waste) ZONE 3-Safety
Before After Location: Additives Storage Tanks Description: Unpainted bundwall Description: Painted bund wall with bright color (yellow) Benefit: Provide clear visibility to see obstacle during performing tank dipping at night-eliminates hazards ZONE 5-Safety
Before After Location: Pump Slap Area Description: Corroded wall at pump slap area Description: Repaint corroded wall at pump slap area Benefit: Avoid corrosion becomes worst and give nice view & environment inside terminal parameter ZONE 4-Cost saving
Before After Location: Loading Bays Description: No proper tagging at pipelines Description: Provided proper tagging at pipelines Benefit: For easy reference during Loading Bays start up & shutdown activity-Eliminate Human Errors ZONE 6-Quality
Before After Location: Loading Bays Description: Messy wiring arrangement at loading baysDescription: Organized properly wiring at loading bays Benefit: Provide safety workplace for the employees, contract workers & drivers-Eliminates physical hazards ZONE 6-Safety
Before After Location: Loading Bays Description: Messy wiring arrangement at guard house Description: Organized properly wiring at guard house Benefit: Provide safety workplace for the workers-eliminates electrical hazards ZONE 1-Safety
Before After Location: Pipelines Description: Faded fire fighting pipelines Description: Re-painted fire fighting pipeline Benefit: Avoid corrosion and give nice view & environment inside terminal parameter ZONE 2, 3, 4, 5 & 6 -Safety
Before After Location: Filling System Description: Old filling system Description: New filling system with dedicated type and area Benefit: Better space arrangement- Eliminates searching waste ZONE 1-Quality
Before After Nil Location: Emergency Evacuation Plan Layout for Office Building Description: Nil Description: Provide emergency evacuation plan layout for office building Benefit: To shows alternatives escape routes during emergency ZONE 1-Safety
Before After Location: Security Check Point with 3D Signboard Description: Nil Description: New security check point with 3D signboard Benefit: Nice view and give good impression to all workers, visitors and customers. ZONE 1-Morale
Before After Location: Loading Arm Sleeves Description: Old Loading Arm Sleeves: UL97 (Red), UL95 (Yellow) & ADO (Brown) Description: New Loading Arm Sleeves: UL97 (Green), UL95 (Yellow) & ADO (Silver) Benefit: Followed truck tagging colors to avoid wrong loading by drivers-Eliminates Human Errors ZONE 6-Quality
Before After Location: Forklift Description: Faded paint on forklift body Description: Re-painted forklift body Benefit: Ensuring the forklift condition do not deteriorate ZONE 6-Cost saving
Before After Location: Work Station Description: Un-organized workstation Description: Organized workstation Benefit: Turn the workplace into a clean, bright place where everyone will enjoy working-Eliminates Searching waste ZONE 1-Quality
Before After Location: Storage for garden equipment Description: Improper storage for garden equipment Description: Proper storage for garden equipment Benefit: Eliminates many kinds of waste, including searching and difficulty in returning an equipment. ZONE 6-Morale