Work place improvement [read only]

PRESENTATION ON
UJJAIN FOODS PVT. LTD.
PRESENTATION ON
WORK PLACE IMPROVEMENT

TARGET FOR PROJECT
Workplace Improvements
Project Details
STATUS AT DSR
STAGE
PHASES-II
Workplace Improvement
TARGET ACHIEVED
A. 5S Implementation
Score Audit Score 16%
Audit Score 30%
(Cumulative)
Audit Score 36%
(Cumulative)
B. Number / Hours of employee
60~201 85
B. Number / Hours of employee
training No training Plan
60~201
Man Hours Training
Topic wise
85
Man Hours Training
Topic wise
C. Visual Management
15%
% Completion of list
made for visual
control
= 30% (Cumulative)
% Completion of list
made for visual control
= 40% (Cumulative)

ACTIVITIES FOR PROJECT
Workplace Improvements
Awareness Training Provided
Team Defined & Display of 5S Zone Managers
5S Red Tag Area & Liquidation Plan Created
1S/2S/3S Massive Derive Started in whole Unit
5S Audits started & 5S RADAR charts Displayed at each zone
Identification & Location marking Done for Zones, Areas, ItemsIdentification & Location marking Done for Zones, Areas, Items
& Equipments
Single Point Photography (BEFORE & AFTER FORMATS)
Yellow Gangways Marking Done
At A Glance & Kaizen Boards Installed
Various Display Boards Made & Some are in Process
Incident Recording System Started
PPEs implemented
Near Miss Identified & Rectified

Awareness Training Provided to All
Employees- TRAINING RECORDS
On-Site Training
has been
provided to allprovided to all
employees on
the 5S, Safety &
Visual
Management on
Regular Basis
(Man-hours- 85)
Sample Record
Format

Distribution of 5S Pocket Cards

5S Red Tag Area & Liquidation Plan
Created
To Remove unnecessary items from work place & to Establish method to
make area free of unnecessary items we created the 5S Red Tag Area and
liquidation for storing the unwanted material

1S/2S/3S Massive Derive Started
in whole Unit
Work inWork in
ProgressProgress
We started the massive derive on 1S/2S/3S in the whole unit and
eliminated the unwanted material of Approx. Rs. 40,000/-

5S Audits started & 5S RADAR
charts Displayed at each zone
On the basis of the 5S audits, RADAR charts updated

5S Scores
2
3
2 2
2
2.5
3
3.5
1 1
0 0
1 1
0
0.5
1
1.5
1S- Sorting 2S- Set in Order 3S- Shine 4S- Standardize 5S- Sustain
Intial Score @ DSR Stage Current Score @ Phase-2

Implementations as per
Visual Audit Check-Sheet
Achieved
40%, Target 30%

Identification & Location marking for
Zones, Areas, Items & Equipments
We have listed down the all the list of the Items, zone etc. for display and
currently displayed on papers printouts

Creation of Model Area-
Extruder
With Epoxy Flooring Paint and Yellow marking of Gangways we have created a 5S
model Area

Single Point Photography
(BEFORE & AFTER FORMATS)
On Next Pages

Company Name: Ujjain Foods Pvt. Ltd Deptt.: All Result: 5S improved
Month:
Aug-17
Subject: 5S Date of Implementation 10.08.2018
Before Improvement
(Photo or Explanation Drawing)
After Improvement
Category
Tick (√)
Applicable
1. Productivity Improvement
(P)
ADD BEFORE PIC/ DRAWING/ SKETCH ADD AFTER PIC/ DRAWING/ SKETCH
2. Quality Improvement (Q)
3. Cost Reduction (C)
4. Improved Delivery (D)
5. Improved Safety (S)
6. Improved Morale (M)
7. Improved Environment (E)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
12. Manpower, Man-hours
Saving
13. Horizontal Deployments
Earlier:
Temporary arrangement for storage of the
caps on the shop floor
Now:
Wooden box with identification for
arrangement/ storage of caps in working area
fixed
Cost Saving/ Year (Rupees)
BENEFITS:-
1. Improved system for the Cap Storage
2. Easy Accesibilty
Suggested By A. Mishra
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Stores Result: 5S improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Improper Layout & Storage of the FG (Puff)
and no identification
Now:
Layout improved with probability of easy
retrieval and identification need to be done Cost Saving/ Year (Rupees)
BENEFITS:-
1. Easy accessibility of Material
2. No Material Mixing
Approved By

Changes in Layout of Dum-
Dum FG Store
Before Variety-
1,2,3,4 & 5 mixed Up Storage
After Variety-
1
Variety-
2
Variety-
3
Variety-
4
Variety-
5
We have re-designed the Layout the FG Store of DUM-DUM Store, according to
the variety. After each variety gap has been maintained. Currently it is in under
trial, we will fix the location by yellow marking in the next stage

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Fryer Result: Safety improved
Month:
July-17
Subject: 5S & Safety Date of Implementation 17.08.2017
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
5. Improved Safety (S) √
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Air gun lying on the floor causing chances of
accidents and damage to the gun
Now:
A small hook welded with the table so that it
can be hanged after use Cost Saving/ Year (Rupees)
BENEFITS:-
1. No Chances of accidents
2. No Damage to the Gun
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Fryer Result: Safety improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Pipes lying in the corner, Causing Place
Making dirty &
Now:
Pipe hanged on the wall
BENEFITS:-
1. Cleaner Place
2. No Damage to the Pipe
3. No Chances of the accidents
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Printer Result: 5S improved
Month:
Aug-17
Subject: Safety Date of Implementation 20.08.2017
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Material Mixing & No Identifications
Now:
No Material Mixing & Identifications done
BENEFITS:-
1. Improved 1S/ 2S Suggested By A. Mishra
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Open Gallery Result: 5S improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
2 Ladders stored along side wall in the gallery,
Occupying More Place
Now:
Ladders hanged on the walls with the help of
hooks Cost Saving/ Year (Rupees)
BENEFITS:-
1. Improved 5S
2. Occupying Less Space
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Masala Result: 5S improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Challi (Jaali ) & other material lying under the
table
Now:
Proper place defined for challi (Jaali)
BENEFITS:-
1. Improved 1S/ 2S/ 3S Suggested By A. Mishra
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Masala Result: 5S improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Improper Material Storage
Now:
Proper Material Storage with details of
identification, Numbering & Location Marking
Done
BENEFITS:-
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Tool Room Result: 5S improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Tools stored in bad condition & Mixed Up
Now:
Tool Shadow Boards Implemented
BENEFITS:-
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Extruder Result: 5S improved
Month:
Aug-17
Subject: 5S & Quality Date of Implementation 28.08.2017
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Gaps in the Floor, due to which material falls
in the lower floor (Ground Floor)
Now:
Gaps filled with welding of the plates with the
floor Cost Saving/ Year (Rupees)
BENEFITS:-
1. Improved 5S & Quality Suggested By A. Mishra
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Store Result: 5S & Safety improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
No Location/ Stand for Sewing Machine &
Weighing Machines
Now:
Location/ Stand for Sewing Machine &
Weighing Machines Defined Cost Saving/ Year (Rupees)
BENEFITS:-
1. Improved Safety & 5S Suggested By A. Mishra
Approved By

VISUAL BOARDS
• 5S VISUAL DISPLAY BOARDS DISPLAYED AT SHOP FLOOR
At 2 Places

PRODUCTION MONITORING BOARDS
IMPLEMENTED
At all Departments

YELLOW GANGWAYS MARKING
Yellow Marking Done:
180 Meters

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Result: 5S Improved
Month:
July-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
No designated path for material movement
Now:
Designated path for material movement
BENEFITS:-
1. Smooth flow of material, as it there was no designated path earlier. So saving material
movement time.
Approved By

Work instructions Made& Displayed,
Started Making the Work Instructions for the Sections, where work Instructions not
displayed and in Next Step will convert all Work Instructions in Permanent Boards
Work Instruction
for MASALA

PPEs Implemented
Masks
We have
implemented
the PPEs
(Personal
Protective
Caps
Aprons
Protective
Equipments)
like:
1. Caps
2. Masks
3. Aprons
4. Gloves
As per the
requirement of
each section

MSDS Made & Displayed
We have made & Displayed the Material Safety Data Sheet (MSDS) for the
Chemical and gases

Near Miss Rectification
On Next Pages

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Extruder Result: Safety improved
Month:
July-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S
9. 5S
10. Space Saving
11. Other
Saving
Earlier:
Pulley Covers Missing , Can Cause Major
accidents
Now:
Pulley Covers fabricated and installed
BENEFITS:-
1. No Chances of accidents Suggested By A. Mishra
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Guard Room Result: Safety improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S
9. 5S
10. Space Saving
11. Other
Saving
Earlier:
Loose & Open Wiring
Now:
Loose Wiring rectified
BENEFITS:-
1. No Chances of Short Circuit Suggested By A. Mishra
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Main Gate Result: Safety improved
Month:
Aug-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S √
9. 5S √
10. Space Saving
11. Other
Saving
Earlier:
Empty & Expired Fire Extinguishers Lying
below the stairs
Now:
Empty & Expired Fire Extinguishers removed
& Refilled Cost Saving/ Year (Rupees)
BENEFITS:-
1. Can be used at the time of mis-happening Suggested By A. Mishra
Approved By

Company Name: Ujjain Foods Pvt. Ltd Deptt.: Stores Result: Safety improved
Month:
July-17
Before Improvement
After Improvement
Category
Tick (√)
Applicable
(P)
8. Energy Saving
9. 5S
9. 5S
10. Space Saving
11. Other
Saving
Earlier:
An Anlge coming out from the floor, Causing
chances of the accidents
Now:
Angle need cut down
BENEFITS:-
1. No Chances of accidents Suggested By A. Mishra
Approved By

AshutoshAshutosh MishraMishraAshutoshAshutosh MishraMishra
(Lean Consultant)(Lean Consultant)
88820317128882031712

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