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

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

International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 223

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.



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.



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) ?


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


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,



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



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

Documents