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Campus of Arvind Ltd.

LEAN MANUFACTURING
IMPLEMENTATION OF 5 ‘S’
Arvind Ltd.
Mysore Road
Bangalore
KNITS DIVISION
07/12/2013
NIFT Kangra, 2010-2014

It has newly been started and has appointed untrained or semi-trained
op...
A SCHEMATIC REPRESENTATION OF A SEWING LINE
ON KNITS PRODUCTION FLOOR
07/12/2013
NIFT Kangra, 2010-2014

3
07/12/2013
NIFT Kangra, 2010-2014

Knits Floor : Project Area

4
ABOUT 5 ‘S’
07/12/2013

SEIRI

5 ‘S’

SEIKETSU

NIFT Kangra, 2010-2014

SHITSUKE

SEITON

SEISO

5
5 ‘S’

What is Involved ?
Segregate
necessary from
unnecessary
Remove what is not
required
Decide on frequency
of sorting
...
07/12/2013

3 ‘S’: SEISO (SPIC
AND SPAN)

4 ‘S’: SEIKETSU
(STANDARDIZATI
ON)

Objective

What is Involved ?

Arranging in ...
5 ‘S’

What is Involved ?

Doing it Right first
time and every time
Sustenance of
good practices.
Setting of efficient
sta...
METHODOLOGY
07/12/2013

Problems Found
 Evaluation before Implementation
 Implementation
 Evaluation After Implementati...
07/12/2013

NIFT Kangra, 2010-2014

PROBLEMS IDENTIFIED
10
•
•
•

•

Packaging materials, Unused cartons,
carton with rejected pieces lying on the
floor

NIFT Kangra, 2010-2014

Bin...
No labelling and no listing of items
on drawers

NIFT Kangra, 2010-2014

Place not defined for the materials

• Violation ...
• Grim and Dirt on floor
• Defect stickers stuck on
floor everywhere.
• No self cleaning done by
operators
• Throwing unus...
4 ‘S’ : Sieketsu

WIP on chair

NIFT Kangra, 2010-2014

5 ‘S’ : Shitsuke

07/12/2013

• No visual guidance for operators.
...
EVALUATION BEFORE IMPLEMENTATION
•

Before Implementation.xlsx
07/12/2013

NIFT Kangra, 2010-2014

IMPLEMENTATION
16
1 ‘S’: SEIRI (SORTING OUT)
07/12/2013

Keep in middle
shelf

Less Frequently

Keep in bottom
or top most
shelf

Not Needed...
1 ‘S’: SEIRI (SORTING OUT)

NIFT Kangra, 2010-2014

•Sorted out the unwanted things.
•The unwanted things discarded.
•E.g....
07/12/2013
NIFT Kangra, 2010-2014

Red Tag Area

19
Name of the object

Authorized Person to
handle
Authorized Person to
dispose

NIFT Kangra, 2010-2014

Quantity

07/12/2013...
2 ‘S’: SEITON (SYSTEMATIC
ARRANGEMENT)
Keyword

3 Points

3 Keys

• Anybody
• Immediately

• Can See
• Can Take Out
• Can ...
07/12/2013

Labeling of fixed positions

NIFT Kangra, 2010-2014

Master Card for
Drawers

22
07/12/2013
NIFT Kangra, 2010-2014

Place defined and labelling done

23
07/12/2013
NIFT Kangra, 2010-2014

Labeling done on cupboards
and maintenance- tool board

24
07/12/2013

Labeling done
•Racks
•Spare Parts of Machine arranged in small cuboids
prepared by us and labeled

NIFT Kangra...
07/12/2013

•Master Card for Files

NIFT Kangra, 2010-2014

•PokaYoke (Error Proofing)

26
07/12/2013
NIFT Kangra, 2010-2014

Output bin as Green color defined and labelled and Input Bin as Blue Colour

27
3 ‘S’: SEISO (SPIC AND SPAN)

CLEANING
TARGETS

Surroundings

Storage Areas

Make Calendars

Equipments &
Machines
3 ‘S’: SEISO (SPIC AND SPAN)

Step 1

Step 2

Step 3

• Visual Observation
of everything

STEPS CARRIED OUT
Shine Calendar...
SHINE CALENDAR FOLLOWED
Shine Activity

Responsible

Timing

Frequency

Before starting of work

Daily

Operator

Toilets ...
4 ‘S’: SEIKETSU (STANDARDIZATION)
STEPS CARRIED OUT
•SOP Cards for sewing hung on each workstations
•Same color sheet, fon...
07/12/2013
NIFT Kangra, 2010-2014

SOP Cards hung on each machine for
ease of operations

32
5 ‘S’: SHITSUKE (SELF DISCIPLINE/
SUSTAIN)
07/12/2013
NIFT Kangra, 2010-2014

•All the workers should be thoroughly inform...
EVALUATION AFTER IMPLEMENTATION


Week 2.xlsx



week 3.xlsx

NIFT Kangra, 2010-2014

week 1.xlsx

07/12/2013



•Can b...
RESULTS AND DISCUSSION
Week 1

Implementation

39/110

Week 3

55/110

65/110

Scores showing execution of 5S on the Knits...
SCORES SHOWING EXECUTION OF 5S ON THE
KNITS FLOOR
07/12/2013

70

50
40
30
20

Before
Implementation
Series 1

NIFT Kangra...
CREDIT WISE IMPROVEMENT IN ALL THE 5
AREAS IN THE EXECUTION OF 5S
07/12/2013

1S
15
10
5S

2S

5
0

4S

WEEK 1
WEEK 2
WEEK...
CONCLUSION

Material handling time is reduced.

Standard procedure eases the
working and training requirements
for operato...
THANK YOU
07/12/2013
NIFT Kangra, 2010-2014

39

BY:
Bhavya Aditya
Surbhi Karn
B.F.Tech (AP), Sem VII
NIFT Kangra
2010-201...
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Apparel internship | NIFT Kangra

  1. 1. Campus of Arvind Ltd. LEAN MANUFACTURING IMPLEMENTATION OF 5 ‘S’ Arvind Ltd. Mysore Road Bangalore
  2. 2. KNITS DIVISION 07/12/2013 NIFT Kangra, 2010-2014 It has newly been started and has appointed untrained or semi-trained operators. Eight teams running with 15-16 workstations One production cabin and one maintenance and trim issue department. The warehouse of the knits is on the first floor. Assembly line Here, an operator finishes her operation; self inspects the quality of work done and then manually passes the panel(s) to the next workstation. 2
  3. 3. A SCHEMATIC REPRESENTATION OF A SEWING LINE ON KNITS PRODUCTION FLOOR 07/12/2013 NIFT Kangra, 2010-2014 3
  4. 4. 07/12/2013 NIFT Kangra, 2010-2014 Knits Floor : Project Area 4
  5. 5. ABOUT 5 ‘S’ 07/12/2013 SEIRI 5 ‘S’ SEIKETSU NIFT Kangra, 2010-2014 SHITSUKE SEITON SEISO 5
  6. 6. 5 ‘S’ What is Involved ? Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting 2 ‘S’: SEITON (SYSTEMATIC ARRANGEMENT) Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting Arranging in order A place for every thing and every useful thing in it’s place. NIFT Kangra, 2010-2014 1 ‘S’: SEIRI (SORTING OUT) Saving & Recovering Space Finding method of Disposal. Finding whose responsibility is to dispose 07/12/2013 Objective 6
  7. 7. 07/12/2013 3 ‘S’: SEISO (SPIC AND SPAN) 4 ‘S’: SEIKETSU (STANDARDIZATI ON) Objective What is Involved ? Arranging in order A place for every thing and every useful thing in it’s place. Clearing the work place / equipment Ensuring –Tip Top condition Making a shine calendar. Achieving higher productivity and better quality. Working methodology (procedures and work instructions) Calendars for every activity NIFT Kangra, 2010-2014 5 ‘S’ 7
  8. 8. 5 ‘S’ What is Involved ? Doing it Right first time and every time Sustenance of good practices. Setting of efficient standards Results should be measureable. Forming the habit Training Every notice board should be updated regularly. Regular evaluation ‘ Visual display of standards Increase the transparency level Easy Induction of New Employee. Clean and Check Standards 07/12/2013 Objective NIFT Kangra, 2010-2014 5 ‘S’: SHITSUKE (SELF DISCIPLINE) 8
  9. 9. METHODOLOGY 07/12/2013 Problems Found  Evaluation before Implementation  Implementation  Evaluation After Implementation  NIFT Kangra, 2010-2014 9
  10. 10. 07/12/2013 NIFT Kangra, 2010-2014 PROBLEMS IDENTIFIED 10
  11. 11. • • • • Packaging materials, Unused cartons, carton with rejected pieces lying on the floor NIFT Kangra, 2010-2014 Bins not kept at their position and defected pieces lying on floor unattended 07/12/2013 • 1 ‘S’ : Sieri Supervisor’s cupboard stuffed with sample. elastic, sample threads etc. Maintenance utilities jumbled up. Tools missing from tool board and drawers Incomplete garments lying in cartons on floor without proper information Defected garments are lying unattended. 11
  12. 12. No labelling and no listing of items on drawers NIFT Kangra, 2010-2014 Place not defined for the materials • Violation of Yellow Lines • No demarcation of places • No listings of the items in the drawers, difficulty in finding out • No labeling on Trim Rack, consuming lot of time to find things 07/12/2013 2 ‘S’ : Seiton 12
  13. 13. • Grim and Dirt on floor • Defect stickers stuck on floor everywhere. • No self cleaning done by operators • Throwing unused or unattended objects anywhere and not in dustbin. NIFT Kangra, 2010-2014 Dustbin cover open and waste are lying outside the dustbin 07/12/2013 3 ‘S’ : Sieso 13 Defect stickers stuck on floor
  14. 14. 4 ‘S’ : Sieketsu WIP on chair NIFT Kangra, 2010-2014 5 ‘S’ : Shitsuke 07/12/2013 • No visual guidance for operators. • No SOP • No single piece movement (Variable WIP at different workstations) • Inappropriate uniform of workers • Workers not following workplace discipline 14
  15. 15. EVALUATION BEFORE IMPLEMENTATION • Before Implementation.xlsx
  16. 16. 07/12/2013 NIFT Kangra, 2010-2014 IMPLEMENTATION 16
  17. 17. 1 ‘S’: SEIRI (SORTING OUT) 07/12/2013 Keep in middle shelf Less Frequently Keep in bottom or top most shelf Not Needed At All Discard Needed But Not Now Red Tag (With proper labeling) Needed But Not Here Red Tag (With 17 proper labeling) NEEDED SEGREGATE NOT NEEDED NIFT Kangra, 2010-2014 More Frequently
  18. 18. 1 ‘S’: SEIRI (SORTING OUT) NIFT Kangra, 2010-2014 •Sorted out the unwanted things. •The unwanted things discarded. •E.g. unused machine manuals discarded, unused and rejected labels discarded, rejected garments put in carton and put in red tag area, Sample elastics put in a carton, Incomplete garment pieces kept in carton put in red tag area and with proper labeling. 07/12/2013 STEPS CARRIED OUT 18
  19. 19. 07/12/2013 NIFT Kangra, 2010-2014 Red Tag Area 19
  20. 20. Name of the object Authorized Person to handle Authorized Person to dispose NIFT Kangra, 2010-2014 Quantity 07/12/2013 Area to which the object belongs Used/Unused Validity Method of Disposal Label to be put on every object in Red Tag Area (fields to be filled as required) 20
  21. 21. 2 ‘S’: SEITON (SYSTEMATIC ARRANGEMENT) Keyword 3 Points 3 Keys • Anybody • Immediately • Can See • Can Take Out • Can Return • Where? • What? • How much? • • • • • • STEPS CARRIED OUT Shelves and drawers arranged Labeling done ( Position defined ) Poka-Yoke for files Master Prepared For each Shelf Layout prepared denoting the position of fans, lights, exhausts etc and workstations positioning Layout.xls
  22. 22. 07/12/2013 Labeling of fixed positions NIFT Kangra, 2010-2014 Master Card for Drawers 22
  23. 23. 07/12/2013 NIFT Kangra, 2010-2014 Place defined and labelling done 23
  24. 24. 07/12/2013 NIFT Kangra, 2010-2014 Labeling done on cupboards and maintenance- tool board 24
  25. 25. 07/12/2013 Labeling done •Racks •Spare Parts of Machine arranged in small cuboids prepared by us and labeled NIFT Kangra, 2010-2014 25
  26. 26. 07/12/2013 •Master Card for Files NIFT Kangra, 2010-2014 •PokaYoke (Error Proofing) 26
  27. 27. 07/12/2013 NIFT Kangra, 2010-2014 Output bin as Green color defined and labelled and Input Bin as Blue Colour 27
  28. 28. 3 ‘S’: SEISO (SPIC AND SPAN) CLEANING TARGETS Surroundings Storage Areas Make Calendars Equipments & Machines
  29. 29. 3 ‘S’: SEISO (SPIC AND SPAN) Step 1 Step 2 Step 3 • Visual Observation of everything STEPS CARRIED OUT Shine Calendar prepared • Practically check everything • Take steps for cleansing • Measure and calibrate •Floor mopped •Windows Cleaned •Kept a separate tea stand (Earlier maintenance department table was used to keep the tea flask) •Racks etc cleaned
  30. 30. SHINE CALENDAR FOLLOWED Shine Activity Responsible Timing Frequency Before starting of work Daily Operator Toilets Cleaning 9:00 a.m. & 1:30 p.m. Daily Housekeeping Sweeping of Floor 9:00 a.m. & 1:30 p.m. Daily Housekeeping Cleaning of Office 9:00 a.m. Daily Housekeeping Workstation Cleaning Wednesday & Person Mopping of Floor Lunch Break Window Panes Any time of the day Once in a week Housekeeping Any time of the day Once in a week Housekeeping Fabric Store/Trim store Saturday Housekeeping
  31. 31. 4 ‘S’: SEIKETSU (STANDARDIZATION) STEPS CARRIED OUT •SOP Cards for sewing hung on each workstations •Same color sheet, font face followed everywhere while labeling •Color for input and output bin. •ID card and Uniform ( apron, scarf, mask and gloves in case of white garment) made compulsory.
  32. 32. 07/12/2013 NIFT Kangra, 2010-2014 SOP Cards hung on each machine for ease of operations 32
  33. 33. 5 ‘S’: SHITSUKE (SELF DISCIPLINE/ SUSTAIN) 07/12/2013 NIFT Kangra, 2010-2014 •All the workers should be thoroughly informed about the recent changes and their benefits •Management Personnel should take care that the rules are followed at all times •Leaders should monitor all the 5S activities continuously. •Create work discipline 33
  34. 34. EVALUATION AFTER IMPLEMENTATION  Week 2.xlsx  week 3.xlsx NIFT Kangra, 2010-2014 week 1.xlsx 07/12/2013  •Can be adapted by changing the worker mentality •Can be adapted by involvement of the people, awareness of this policy and the huge cost involvement in implementation. •Top management involvement is necessary 34
  35. 35. RESULTS AND DISCUSSION Week 1 Implementation 39/110 Week 3 55/110 65/110 Scores showing execution of 5S on the Knits Floor Score for each S ( Credit Wise ) Week 1 Week 2 Week 3 1S ( 25 ) 7 11 12 2 S ( 15 ) 11 17 15 3 S ( 25 ) 9 16 18 4 S ( 25 ) 6 5 8 5 S ( 20 ) 6 6 NIFT Kangra, 2010-2014 28 / 110 Week 2 07/12/2013 Score Before 12 Credit wise improvement in all the 5 areas in the execution 35
  36. 36. SCORES SHOWING EXECUTION OF 5S ON THE KNITS FLOOR 07/12/2013 70 50 40 30 20 Before Implementation Series 1 NIFT Kangra, 2010-2014 60 Series 2 Series 3 10 0 36
  37. 37. CREDIT WISE IMPROVEMENT IN ALL THE 5 AREAS IN THE EXECUTION OF 5S 07/12/2013 1S 15 10 5S 2S 5 0 4S WEEK 1 WEEK 2 WEEK 3 NIFT Kangra, 2010-2014 20 3S 37
  38. 38. CONCLUSION Material handling time is reduced. Standard procedure eases the working and training requirements for operators The defective items are reduced. NIFT Kangra, 2010-2014 Reducing the stoppage time of the machine increases the overall quality of product. 07/12/2013 The floor space is utilised properly. Employee involvement is improved. Easier and safer work environment is partly achieved. 38
  39. 39. THANK YOU 07/12/2013 NIFT Kangra, 2010-2014 39 BY: Bhavya Aditya Surbhi Karn B.F.Tech (AP), Sem VII NIFT Kangra 2010-2014

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