1. SAN FERNANDO VALLEY PALLET COMPANY
'5S' PROJECT
MSE 507
Lean Manufacturing Systems
Spring – 2016
Project Guide:
Professor S. Jimmy Gandhi
Team 04
Renan Gama
Viralkumar Jayswal
Perparim Rushiti
Pooja Chintakunta
Ranmini Menikdiwela

2. Content
• 5S Methodology
• Company Introduction
• About Pallet Production Process
• How to Implement 5S?
- Sort
- Set
- Shine
- Standardize
- Sustain

3. 5S Methodology
Main idea about 5S implementation in organization is to make, clean, tidy and well
organized workplace.
S1 - Sort S2 - Shine
S3 -
Standardize
S5 - Sustain
S3 - Set in
order
Start
We implement 5S,
• Company : San Fernando Valley Pallet
• Area : Production Division

4. Company Introduction
• San Fernando Valley Pallet Co. is a Family owned business which is being operated
since 1996.
• It provides all types of pallets, from standard pallets and crates to custom sizes,
per customer specifications.
• Their pallets are designed with innovation for maximum capacity.
• They have two multiacreage facilities to serve better in Southern California. They have
more than 20,000 pallets in stock and keep inventories of custom and standard sizes
to meet customers’ requirements.
• They are Certified Pallet Maker for Export Pallets.

5. Pallet Production Process
No New Pallet Construction Process Old Pallet Construction Process
1 Cut cants into specific sizes (required
length, height and width)
Sort old pallets
2 Butt joins short length wooden pieces Dismantle the wooden pallets
3 Place the pallet elements on the line Refurbishment - Join pallet components
(runners) using nailing machine
4 Join pallet components (runners) using
nailing machine x 2
Finished pallets temporally stored in the
production line
5 Finished pallets temporally stored in the
production line
Finally transfer to the main storage area
6 Finally transfer to the main storage area

6. How to Implement 5S in Pallet
Production Process?

7. SORT Sort is a practice of removing all the unnecessary materials from the
current production process and keeping only the essential items.
Problem:
• Production floor become messy and crowded
• Unnecessary time for searching tools and other materials
• Unwanted inventory and machineries are costly to maintain and required significant amount of work
space
• Excess stocks hide the production problems hence unneeded items and equipments make harder to
advance the process flow

8. How we can sort?
Eliminate nonessential items from the work place such as wood pieces, tools, machines
and other materials.
• Specify separate location as Red Tagged area.
• Red Tagged items, which are nonessential.
• Create a “Local Red Tagged” and stored nonessential items in the local red tag area
for 5 days.
• We proposed to have one local red tagged area in production floor.
• If the production team not reclaimed any red tagged items within 5 days, items are then
moved to “Central red tagged” area.
• One central red rag area to be introduced to the entire manufacturing floor.
SORT

9. • Those items are located in the central red tag area for another 5 days.
• Everyone can sift through the items to check whether they have anything need.
• Thereafter, company can disposes of them through recycling, resale or trash.
SORT How we can sort?

10. SET
• SFV Pallet Current Layout
Arranged required items in a way that easy to use.

11. How to Set in order?
• Three major production Areas: “Assembly Custom Sized Pallets”, “Assembly regular
Sized Pallets” and “Repair Regular Pallets”.
SET
1. Proposal of New Layout

12. • Thereafter we analyzed the production process in order to find the additional
improvement opportunities such as ways to reduce waste and errors and
make palette production area more visually instructive.
2. Visually instructive
• Label items: Palette nailing machines, tables and other tools to be labeled
(Labeling items will help everyone to find items easily and put them back at
the right place. This helps to reduce unnecessary motion, searching waste,
human energy waste and unsafe conditions)
• Display safety alert: Alerting people will improve safety
• Display procedures: Display standard SOPs/operation steps
SET How to Set in order?
1. Proposal of New Layout

13. Pallet assembly table design 1 :
Table slope can be adjustable
Pallet assembly table design 2 :
Pallet can be rotate or spin easily
3. Reduce waste/errors: Pallet assembly table designs
SET How to Set in order?

14. Pallet assembly table design 3
Suspend the pneumatic nailing tool
SET How to Set in order?
3. Reduce waste/errors: Pallet assembly table designs

15. • Quality standards need to be presented in graphically or physically
• Find out critical to quality operations
• Visually display those operation’s, acceptable and unacceptable outputs in a common
area
4. Quality Inspection
SET How to Set in order?
Acceptable Unacceptable

16. SHINE Keep clean the workplace every day by eliminating dirt and
dust.
Problem:
Wood dust and other dust particles cause injuries/health
issues.
Machines that do not receive sufficient maintenance,
tend to breakdown or cause defects.
Untidy appearance at workplace.

17. How to shine the workplace?
• Establish a regular schedule for cleaning every day –
- Routing cleaning everyday end of the shift (15 min before)
- Deep cleaning every Friday, 30 min before the shift end
(Clean things such as tools, equipments, pallet making tables/jiggers and work floor)
• Each team member need to be equipped with adequate cleaning supplies
• Cover storage & production area well to protect by weather condition
SHINE
Kärcher Industrial vacuum cleaners IVC-Series for
wood industry
https://www.youtube.com/watch?v=0q6A63ZYEm4
Cost = $450 - $500 each

18. STANDARDIZE
How to standardize the workplace processes?
Instructions and Training –
• Instructions for operations (Standard Operating Procedures - SOPs) must be provided,
in order to standardize the methods and practices for each operation.
• Training may be necessary in order to reinforce the procedures and practices for each
operation.
Visual Aids -
• Visual aids, such as signs, arrows, lines must be implemented in the operation area.
• Different colors of labels, signs, and lines can be used for the different kinds of pallets
• New/Old palettes, Finished/Unfinished palettes, Rejected palettes
• Different lengths of cut wood, different colors of labels can be used (so that the worker
will easily identify the material needed)
All the best practices and new procedures recommended
the previous 3 steps must be standardized

19. • For the different operations, different colors of lines can be used to surround the
operation area, each color meaning a different level of risk. So, operations which can
offer more danger, can be surrounded with a vivid color line in the ground, which will
make easier to workers identify risky areas and will increase safety.
STANDARDIZE
How to standardize the workplace
processes?

20. • In order to mark the floor with the safety lines, it is better to buy a floor marking, to paint it
manually, or buy the tape and mark it manually.
Breaks
• After every break, (lunch break, shift) workers must put all the tools and equipments back
to the place where it belongs before leave the workplace.
• For the lunch break, a specific place should be dedicated. In this place the workers should
have the microwave, tables, chairs, water, and so on. Doing that it is easier to keep the
workplace clean, avoid potential contaminations/intoxications, and the safety is increased.
Prices
• Vinyl Safety Marking Tape $8-
~$12 at Amazon.
• 3M Lane Marking Applicator
$150 at Amazon.
STANDARDIZE
How to standardize the workplace
processes?

21. SUSTAIN
How to sustain in correct procedures?
• Conduct a regular auditing procedure in order to ensure that employees understand
the importance of proper work place organization.
• Create a “Housekeeping Scorecard” to analyze the team performance in monthly
basis.
• Further the audit provides a good opportunity to get employees feedback for future
improvements.
• Culture change - this is not something to be done just one time, it is something to be
introduced to the company culture in order to maintain the practices.
Making a habit of properly maintain the correct
procedures

22. 5S Housekeeping Scorecard
5S Housekeeping Scorecard
Date : 0 – No Problems
1 – One to Two Problems
2- More than Two Problems
Auditor :
Location :
N/A 0 1 2 Description
Sort
1 No unnecessary materials in area.
2 Unused wooden pieces are out of the work area.
3 No unnecessary equipments, machines and personal items.
Set In Order
4 Tools and equipments are properly identified and stored in designated area.
5 Pallet assembly tables are cleaned and organized.
6 Finished pallets temporally storing area cleaned and organized.
7 Machines are properly identified and properly located.
Shine
8 Pallet assembly table surface, tops of machines free of dust.
9 Floors are cleaned around the work area.
10 Work stations clean and organized.
Standard
11 Damaged/non functional equipments are removed from the work area.
12 Machines are properly maintained.
13 Properly maintained red tag procedures.
14 Properly follow the pallet construction process
15 Properly follow the safety instructions
Total

23. SAFETY
• 5S + Safety = 6S
• Although safety is already included in the traditional 5 steps;
–Clean workplace -> Safer workplace;
–Well maintained equipment -> Safer equipment.
• Concentrate on safety aspects of your initiative, reviewing every action and
each area to ensure that you have not overlooked any potential hazards.
–In the sort phase, besides red tags, use yellow tags to Environmental
Health & Safety hazards (evaluated separately);
–Display safety alert: Alerting people will improve safety;
Eliminate Hazards

24. Questions?

25. Thank you…