RECTIFICATION IN PLANT LAYOUT BY IMPLEMENTATION OF 5S · 2017-04-14 · 4. Location for containers, Boxes, Bines, materials is not clearly defined. 5’S STRATEGY . 5S is a strategy
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RECTIFICATION IN PLANT LAYOUT BY IMPLEMENTATION OF 5S
Abhay Tiwari1, Rishabh Dubey
2
Student, Mechanical department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat
Corresponding Author Detail:
Abhay Tiwari
Student, Mechanical department,
Laxmi institute of Technology,
Sarigam-Valsad, Gujarat.
Internal Guide Detail:
Mr. Ashish Patel
Assistant Professor, Mechanical department,
Laxmi institute of Technology,
Sarigam-Valsad. Gujarat.
ABSTRACT
5S is a basic foundation of Lean manufacturing systems. It is a tool for cleaning, sorting,
organizing and providing the necessary groundwork for workplace improvement. This
research effort dealt with the implementation of 5S methodology in the Prime Housewares
Private limited, Somnathroad, Dhabel, Daman. A detailed application of the 5S system is
given. It will impact the instructors and workman of Industry that work within the selected
place. By following the 5S methodology, this research effort may show significant
improvements to safety, productivity, efficiency, and housekeeping. The research documents
improvements by using before and after pictures. It also intends to build a stronger work ethic
within the workman and engineer who would be expected to continue the good practices.
KEYWORDS: 5S, Workplace Management.
INTRODUCTION
Plastic moulding is very widely used process in today‟s world. Due to the high cost of
metallic materials and their lack of availability the plastic materials are very widely used in
many applications. The plastic material has very good qualities and their qualities can also be
improved easily by the use of catalyzers. Thus plastic moulding is getting very high attention.
Plastic moulding has very wide classification. Plastic products with simple shapers are easy
to manufacture. But products with complex shapes are difficulty to manufacture the injection
moulding is used. Injection moulding machines are used for their high productivity and high
quality of production. In injection moulding the products which require uniform thickness
with high density are easy to manufacture. The plastic moulding industries are replacing their
conventional machines by the injection moulding machines due to their high productivity and
user friendly control.
In Prime Housewares,Private limited by conducting study that helped us to identify the
problems with the environments, safety and cleanness of the industry.5S is a system to reduce
waste and optimize productivity through maintaining an orderly workplace and using visual
cues to achieve more consistent operational results the term refers to five steps – sort, set in
order, shine, standardize, and sustain – that are also sometimes known as the 5 pillars of a
visual workplace. 5S programs are usually implemented by small teams working together to
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get materials closer to operations, right at workers‟ fingertips and organized and labeled to
facilitate operations with the smallest amount of wasted time and materials.
“A place for everything, and everything in its place” is the mantra of the 5S method, and
storage and workspace systems such maximum use of cubic space for the highest density
storage. The result is an improved manufacturing process and the lowest overall cost for
goods produced.
COMPANY INFORMATION
Name of Industry: Prime Housewares limited.
Address: 39A, GDDIDC, Somnath, Daman 396210.
Product produces:
Mug
Fruit Container
Buckets
Bowls etc.
Process:
This is small industry. In which plastic granules is used as raw material and this raw material
is converted by injection moulding process into the finish good or different parts. First raw
material from the store is taken to manufacturing unit. After it is inspected and then it is send
to mixing room where mixing is carried out. After mixing again inspection is done that
pigment is properly mixed or not. Then after inspection plastic injection is done with the
machine. Then finishing is done. then it is send to packing department where final product is
packed.
AREA OF STUDY
Objective of study:
To keep the work place cleans, efficient and safe.
Problem identification:
While studying, identified problems are:
1. Tools (moulds) are not properly kept.
2. Need of cleanliness and tidiness.
3. Spare parts and materials are present in workplace.
4. Location for containers, Boxes, Bines, materials is not clearly defined.
5’S STRATEGY
5S is a strategy for attaining workplace organization and cleanliness, and it will improve
quality, productivity and moral than any other lean manufacturing improvement. Below
fishbone diagram shows various phases of 5‟S methodology. In each phase, we have
described the problem by using this phases we have solved the work place management
problem.
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
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Figure-1 Fishbone Diagram
The first 'S' stand for Seiri (Sort). It is a waste reduction step; all materials are separated as
necessary and unnecessary. Sorting lamination of waste materials (raw materials, tools and
material) and damaged tools. To sort out necessary and unnecessary materials red tag is used.
It‟s helps to maintain the clean workplace and improves the efficiency of searching and
receiving things, shortens the time of running the operation. In sorting we distinguished the
useful and scrap items.
Figure-2 Before sorting
Figure-3 After sorting
The second „S‟ stands for Seiton (Set in order). The materials that were separated in earlier
stage is stored orderly and labeled, so as to it will easily found whenever required. It will
reduce the time required for searching the materials and tools.
Figure-4 Before
Figure-5 After
The third „S‟ stands for Seiso (shine), It is related to the cleaning, shine and sweeping of
workplace and machinery. During cleaning, it is checked the cleanness of machine,
workplace area, and sources of light, preventive maintenance of the machinery and
equipment etc.
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
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The fourth „S‟ stands for Seiketsu (standardize), In this step standard procedure, audit
sheet and work instructions are prepared to maintain Seiso. Before starting of work to check
and correct the sorted items, placing equipment‟s at its place and cleaning etc, and
give proper reading on audit sheetand create awareness in employee to maintain this thing on
production line or on nonproductive line. Score Condition Observed
0 1 2 3 4 To calculate 5S score4 Very Good (perfect condition) 1. Add up each column
3 Good (1-2 problems) 2. Add each column together to get total
2 OK (3-4 problems) 3. Divide total by 280
1 Bad (5-6 problems) 4. Multiply this score by 5
0Very Bad (above 7 problems),
or non existant5. This is now your 5S score
Date :_____________________________ Audited By :_________________________ Area Audited : _________________________
Number Item
Sort
(Means removing from the
workplace all items that are
not needed for current
production)
Straighten
(Can be defined as arranging
items so that they are easy to
use and labelling them so that
they are easy to find and put
away)
Shine
(Means sweeeping floors,
wiping off machinery, and
generally making sure that
everything in the factory stays
clean)
Standardise
(It is the state that exists
when the first three S's are
being maintained)
Sustain
(Making a habit of properly
maintaining correct
procedures)
0 1 2 3 4 0 1 2 3 4 0 1 2 3 4 0 1 2 3 4 0 1 2 3 4
1 H & S
Are there fire extinguishers,
fire exits clear, PPE available,
eye wash stations and first
aid equipment available
All fire extinguishers are
charged, eye wash stations
labelled and first aid
equipment available and
labelled
Are safety glasses clean and
in good condition
Area plan identifies eye wash
stations, fire extinguishers,
and fire exits
Are PPE and safety
standards being adhered to by
all employees in the area
2 Environmental Are recyclable materials in
non-recyclable containers
Each area has specified
recycling containers
All outside surfaces of
recycling containers are clean
Waste disposal standards
exist and are displayed
Employees in the area are
using the containers to
standard
3 FacilitiesAre facility items in the area
broken, damaged
Have items in the area been
identified that are broken or
damaged ?
The area has floors swept,
machinery clean and
generally clean
Has maintenance request
been raised ?
Does an area have a planned
maintenance schedule for all
facilities issues ?
4 Floors & Gangways Free of obstructionsFloor Marked per plant
standard
Clean (No Dirt, No Spills, No
Oil)
Floor marking standard
created and posted in the
area
Daily checksheet in place
with sign off & date with
improvement action items
5 Duty TechnicianDoes Duty technician rota &
standard existRota is displayed and labelled
Is rota board clean / good
condition
Duty technician standard
exists for the area
Duty technician rota is being
carried out to standard
6 Tooling, Fixtures, JigsNo Tools, fixtures & jigs on
workstations unless in use
Point of use Items have
designated and clearly
organized storage location
No tooling (measuring
equipment, torque wrenches,
pressure gauges) in area out
of calibration
Area plan identifies location of
tooling, fixtures & jigs
Are all tooling standards
adhered to at all times ?
7 Wires , cabling & HosesNo un-used wiring, & hoses
present or trailing
Are all Wiring , cabling and
hoses organised and
identified?
Are all hoses, cabling & wires
clean, in good condition and
blanked (hoses only) ?
Area plan identifies location of
wires, cabling & hoses
Are all wires, cabling & hose
standards adhered to at all
times ?
8 Workbenches & surfacesNo un-necessary items on
workbenches or work surfaces
Workbenches and work
surfaces are organized
Workbenches and work
surfaces are clean and in
good condition
Does a standard exist in the
area that describes what the
workbenches and surfaces
should require
Are all workbenches &
surfaces standards adhered to
at all times ?
9 Visual tracking boardsAll information is current and
necessary ?
Department visual tracking
board layout constant with
plant standard
All postings are neat & orderly
in appearance
Area standard exists and is
posted to define layout and
format
Are all visual tracking board
standards adhered to at all
times ?
10 Red TagAre there items requiring red
tags within the area
Red Tag area is designated
and labeled, all items tagged
with date placed in area
Red tag area to be cleanArea plan identifies red tag
area
Red tag area is maintained to
correct procedure
11 Mobile EquipmentNo un-necessary mobile
equipment present
Storage locations for mobile
equipment are designated and
labeled
All are free of debris and none
are damaged
Area plan identifies location
mobile equipment
Mobile equipment is located
in correct area when not in
use
12 StorageNo material storage areas are
overflowing
All material storage areas are
clearly designated and labeled
Material storage areas only
contain WIP and/or pre-kitted
items
Area plan identifies location of
material storage
Items are returned to
designated area when not in
use
13 Cleaning StandardsCleaning standards and or
cleaning station exist
Cleaning standards &
cleaning station are
designated and labelled
Cleaning equipment is stored
in correct location and in good
condition
Cleaning standards exist and
have daily sign off and date
Daily cleaning standards are
adhered to
14Machine Guards, Windows &
InterlocksAll interlocks are operational
Guards and shields in place
where required
All machine windows are
cleaned regularly to area
standard
Machine guards, interlocks
have planned maintenance
standard and schedule
Machine guards, interlocks
are maintained to planned
maintenance standard
C:\Users\mayankdubey\Desktop\project IDP\[5S audits check sheet and comments sheet -issue2.xls]5S ChecksheetGRAND TOTAL
5S SCORE
Score
/ 280
Score
SECTION TOTALS : / 56 / 56
PRODUCTION 5S CHECKSHEET
/ 56
Score (check box)
/ 56 / 56
Score Score Score
Figure-6 Production 5S checksheet
The fifth „S‟ stands for Shitsuke (sustain), Sustain is about the mental and physical
disciplines required to maintain the other Seiketsu items. It is done with help of co - operation
between employees, store keeper, engineer and manager.
RESULTS AND DISCUSSION
No. Process Before
(min) After(min)
Increased
Effectiveness (%)
1 Mould searching time (average) 3.14 1.34 0.5732
2 Raw material traveling time 4.3 2.4 0.4418
3 Mould arrangement 3.18 1.52 0.522
4 Overall change in percentage 10.62 5.26 50.47%
Table-1 Result
Time Analysis of Implementation of 5S Time analysis or Time comparison play an important
role in a company or industry to improve working and productivity efficiency. Time analysis
nothing but comparison of operation time means how much time take by the process,
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 226
manufacturing of product, searching of tools and materials, etc., We have implement 5S in
Filter Leading company, what is effectiveness after implementation of 5S we have recorded
and compared it with old record, effectiveness of 5S before and after implementation is given
above Table.
CONCLUSION
The 5S is an effectiveness to manage tools and materials which can improve
housekeeping, environmental conditions and health and safety standards and increase
productivity and quality. 5S sort stage eliminates unused, unwanted material from the
storage room which reduces clutter. Set in order allocates space for components, due to
this it give more space for storing more material and tools and results in reduction in
searching time. 5S reduce the searching time and improve the production and quality of the
products and employees and organization become self-disciplined.
REFERENCES
1. Aziz Wan Asri Wan Abdul, Mat Azman Che, “The Effectiveness of Implementation of
5S on Employee Motivation”,Business and Social Sciences Review (BSSR), Vol. 1, No.
1, pp. 41-51, 2011.
2. Osada T. “The 5S: Five Keys to a Total Quality Environment”, Asian Productivity
Organization, Tokyo.1991
3. Nilipour Akbar, Jamshidian Mehdi, “5S As an Environmental Organization Management
Tool; Benefits and Barriers”, 3rd International Management Conference, pp.1-10, 2005
International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017
IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 227
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