The document summarizes the implementation of a 5S program by a Polish manufacturing company called BIANOR. It describes initial resistance from employees who did not see the benefits, so a pilot project was conducted to sort, set in order, and clean one area over 5 days. This helped employees realize the benefits of 5S. The challenges were then stabilizing and sustaining the 5S practices long-term across the whole organization by developing procedures and audits to maintain the changes.

1. THE HUMAN FACTOR IN 5S
IMPLEMENTATION: PERSPECTIVE FROM
POLAND
Submitted by:
Akanksha Kataria
Ayush Gupta
Chandan kumar
Tushar Garg

2. CASE OVERVIEW
• Implementation of 5S by a Polish production
company- BIANOR
• Shows the specifity of implementation process by
taking into consideration the attitudes of employees
• Highlights the aspects of organization culture

3. ABOUT THE COMPANY- BIANOR
• Polish manufacturing company (injection moulding)
• Specialize-
• Assembly of components where plastic is the main component
• Printing, painting, in-mould labeling and finishing
• OEM for brands like Philips, BSH, Graco, Makita
• 320 employees – 4 shift system – 24/7 productivity
• Monthly product

4. 5S

5. • SORT- REMOVE UNECESSARY MATERIALS
• SET IN ORDER- LOCATE NECESSARY MATERIALS
• SHINE- REMOVE DIRT
• STANDARDIZE-
• SUSTAIN- SUPPORTING , CONTINIOUS IMPROVEMENT

6. ADVANTAGES
• Time saving
• Quick Retrieval
• Accidents and mistakes minimized
• Increases space
• Creates workplace ownership

7. INITIAL PHASE OF 5S IMPLEMENTATION
• Some of the Employees were against 5S
• Reason
• Lack of consistency
• Time consuming
• No Benfits found in the first 2 months
• Not following the steps accordingly
• Production reduction which led to not enough quarterly bonuses
• They didn’t have enough time for cleaning.

8. PILOT PROJECT
• Coordinator- Kate
• Build implementation plan for 5 days
• 5s
• 1st day - Sorting
• 2nd day- all the essential items
• 3rd day- shining state
• 4th day- checklist was created
• After taking the above steps they were able to realise
that 5s is beneficial for the organization

9. PROBLEM
• The implementation of next 2 steps
• Stabilize
• Sustain
• Spreading of 5s in whole organization
• How to implement the above steps ?

10. SOLUTION
• Standardize
• Develop procedures, schedules and practices
• Regularly audit using Checklist
• Continue to keep it clean and dispose the unnecessary.
• Generate a maintenance system
• Sustain
• Make it a way of life.
• Part of Health and safety
• Involve the whole workforce.
• Develop and keep good habits.