The main objective of this study is to assess the implementation of 5S and development of the 5S Activity Checklist in manufacturing companies. The scope for this study covers the following areas: identifying problems, looking into critical success factors, their outcomes and recommendations. In addition, factors that may act as constraints to the implementation of the 5S activity and possible solutions for the industries are also identified through observation and evaluation of the improved environmental performance. The study is conducted using a systematic approach with specific software in order to get the most accurate results.
This document reviews the 5S technique, which is a lean manufacturing method for organizing and cleaning the workplace. It consists of five Japanese words: seiri (sort), seiton (set in order), seiso (shine), seiketsu (standardize), and shitsuke (sustain). The 5S method aims to reduce waste and optimize productivity, quality, and safety. It involves sorting out unnecessary items, arranging necessary items efficiently, thoroughly cleaning the area, standardizing processes, and sustaining the new systems. Implementing 5S can improve quality, productivity, efficiency and overall performance by creating an effective, clean and safe work environment.
IRJET- Implementation of 5S in the Manufacturing IndustryIRJET Journal
This document discusses the implementation of 5S methodology in manufacturing organizations. It begins with an abstract describing 5S as a quality improvement technique consisting of five Japanese terms that translate to Sort, Set in Order, Shine, Standardize, and Sustain. The document then provides background on 5S and lean manufacturing before analyzing issues at a small-scale manufacturing company. It details the methodology used to implement 5S through establishing teams and zones. Finally, it explains the five steps of 5S - Sort, Set in Order, Shine, Standardize, and Sustain - and provides guidelines for practicing the first S, Sort. The overall purpose is to examine how 5S can be applied to improve organization, efficiency, safety and productivity
The document discusses the 5S methodology for workplace organization. It provides an overview of what 5S is, which is a system to establish a clean and organized work environment. The 5 key elements of 5S are also defined: Sort, Set In Order, Shine, Standardize, and Sustain. Benefits mentioned include improved productivity, safety, and employee morale. Before and after photos show the transformation of areas that have implemented 5S. Testimonials from team members express support for the 5S system and its results in their work areas.
This document discusses Kaizen, a Japanese philosophy of continuous improvement in manufacturing processes. It defines Kaizen and outlines its dual nature as both an action plan and philosophy. The 5S framework and the cycle of Kaizen activity are described. A case study is presented on applying Kaizen at Elin Company to balance their assembly line and reduce cycle times, resulting in improved productivity. A SWOT analysis of Elin Company is also provided. The document concludes that Kaizen can help organizations outperform competitors through optimal resource use, and recommends training employees and maintaining open communication.
A Review on Performance Management and Appraisal in Construction Industry Tow...IRJET Journal
This document reviews performance management and appraisal in the construction industry and its impact on project performance. It discusses various frameworks for performance measurement and defines performance management and appraisal. It identifies factors that affect performance like attendance, quality of work, job knowledge, and behavioral factors. The document outlines the objectives, need, and scope of studying performance appraisal in the construction industry. It discusses various researchers' statements on tools for performance evaluation and developing a performance management process. Finally, it concludes that focusing on identified performance, behavioral, grading, personal effectiveness, and social factors can improve employee performance and increase project profits.
Standardization & digitalization of sewing operationsArpan Mahato
This document outlines a project to standardize and digitize sewing operations using lean principles. It involves analyzing current work procedures, comparing them to General Sewing Data (GSD) standards, and developing new standardized worksheets (STWs) where needed. 12 styles across 21 modules were examined. For styles with STWs, they were analyzed against GSD and improved. For styles without STWs, new ones were created from the GSD. The goal is to remove inconsistencies and optimize operations to increase productivity and quality according to lean methodology.
5S Priciples TQM-Total Quality managementDHARMARAJ M
A quality circle is a small group of volunteers from the same department who meet regularly to address quality issues. The objectives are to improve quality, productivity, communication and motivate employees. A quality circle has a steering committee, coordinators, facilitators, circle leaders and members who meet to identify and solve work problems. Implementing quality circles can benefit employees through increased job satisfaction, self-development and improved relationships.
The document summarizes the implementation of 5S practices in a manufacturing setting. It describes the 5S process which includes Sort, Set in Order, Shine, Standardize, and Sustain. Implementing 5S provided several benefits such as increased productivity, improved employee morale, reduced waste, and a safer work environment. Data was collected before and after the implementation, which showed improvements in various areas and processes. Suggestions included adding more testing and inspection machines to eliminate bottlenecks. In conclusion, implementing 5S and visual controls led to better space utilization, safety, accuracy, and inventory management.
This document reviews the 5S technique, which is a lean manufacturing method for organizing and cleaning the workplace. It consists of five Japanese words: seiri (sort), seiton (set in order), seiso (shine), seiketsu (standardize), and shitsuke (sustain). The 5S method aims to reduce waste and optimize productivity, quality, and safety. It involves sorting out unnecessary items, arranging necessary items efficiently, thoroughly cleaning the area, standardizing processes, and sustaining the new systems. Implementing 5S can improve quality, productivity, efficiency and overall performance by creating an effective, clean and safe work environment.
IRJET- Implementation of 5S in the Manufacturing IndustryIRJET Journal
This document discusses the implementation of 5S methodology in manufacturing organizations. It begins with an abstract describing 5S as a quality improvement technique consisting of five Japanese terms that translate to Sort, Set in Order, Shine, Standardize, and Sustain. The document then provides background on 5S and lean manufacturing before analyzing issues at a small-scale manufacturing company. It details the methodology used to implement 5S through establishing teams and zones. Finally, it explains the five steps of 5S - Sort, Set in Order, Shine, Standardize, and Sustain - and provides guidelines for practicing the first S, Sort. The overall purpose is to examine how 5S can be applied to improve organization, efficiency, safety and productivity
The document discusses the 5S methodology for workplace organization. It provides an overview of what 5S is, which is a system to establish a clean and organized work environment. The 5 key elements of 5S are also defined: Sort, Set In Order, Shine, Standardize, and Sustain. Benefits mentioned include improved productivity, safety, and employee morale. Before and after photos show the transformation of areas that have implemented 5S. Testimonials from team members express support for the 5S system and its results in their work areas.
This document discusses Kaizen, a Japanese philosophy of continuous improvement in manufacturing processes. It defines Kaizen and outlines its dual nature as both an action plan and philosophy. The 5S framework and the cycle of Kaizen activity are described. A case study is presented on applying Kaizen at Elin Company to balance their assembly line and reduce cycle times, resulting in improved productivity. A SWOT analysis of Elin Company is also provided. The document concludes that Kaizen can help organizations outperform competitors through optimal resource use, and recommends training employees and maintaining open communication.
A Review on Performance Management and Appraisal in Construction Industry Tow...IRJET Journal
This document reviews performance management and appraisal in the construction industry and its impact on project performance. It discusses various frameworks for performance measurement and defines performance management and appraisal. It identifies factors that affect performance like attendance, quality of work, job knowledge, and behavioral factors. The document outlines the objectives, need, and scope of studying performance appraisal in the construction industry. It discusses various researchers' statements on tools for performance evaluation and developing a performance management process. Finally, it concludes that focusing on identified performance, behavioral, grading, personal effectiveness, and social factors can improve employee performance and increase project profits.
Standardization & digitalization of sewing operationsArpan Mahato
This document outlines a project to standardize and digitize sewing operations using lean principles. It involves analyzing current work procedures, comparing them to General Sewing Data (GSD) standards, and developing new standardized worksheets (STWs) where needed. 12 styles across 21 modules were examined. For styles with STWs, they were analyzed against GSD and improved. For styles without STWs, new ones were created from the GSD. The goal is to remove inconsistencies and optimize operations to increase productivity and quality according to lean methodology.
5S Priciples TQM-Total Quality managementDHARMARAJ M
A quality circle is a small group of volunteers from the same department who meet regularly to address quality issues. The objectives are to improve quality, productivity, communication and motivate employees. A quality circle has a steering committee, coordinators, facilitators, circle leaders and members who meet to identify and solve work problems. Implementing quality circles can benefit employees through increased job satisfaction, self-development and improved relationships.
The document summarizes the implementation of 5S practices in a manufacturing setting. It describes the 5S process which includes Sort, Set in Order, Shine, Standardize, and Sustain. Implementing 5S provided several benefits such as increased productivity, improved employee morale, reduced waste, and a safer work environment. Data was collected before and after the implementation, which showed improvements in various areas and processes. Suggestions included adding more testing and inspection machines to eliminate bottlenecks. In conclusion, implementing 5S and visual controls led to better space utilization, safety, accuracy, and inventory management.
A presentation on The Kaizen Pholosophy, a well known workplace management philosophy originated in Japan.
The application of this philosophy has led to the success of several companies like Toyota and Canon.
KAIZEN: A Lean Manufacturing Techniquevivatechijri
Now-a-days the ultimate goal of all industries is to enhance productivity through simplified system
and incremental improvements by applying some modern available techniques. At present, many manufacturing
companies are facing problems such as high quality rejection, high inventories, high lead time, high costs of
production, and inability to cope with customer orders. By implementing and practicing the lean production
system many problems can be solved without employing high-tech and high-touch approaches but by involving
people on the shop floor in Kaizen activities. For continuous improvement in an organization, Japanese
philosophy Kaizen is very popular. Flawless concepts of Kaizen methodology and proper implementation of tools
can lead to a successful kaizen program in a company. Kaizen is one of the powerful tools of lean manufacturing.
Kaizen refers to continuous improvement in performance, cost and quality. Kaizen ensures that manufacturing
processes become leaner and fitter, but eliminate waste (problem) where value is added. The main objective of
this paper is to provide a background on kaizen, present an overview of kaizen concepts that are used to transform
a company into a high performing lean enterprise.
The 5S methodology is a workplace organization method originally developed in Japan that consists of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. The methodology involves sorting, setting in order, shining, standardizing, and sustaining a clean, orderly work environment. It is designed to increase efficiency, quality, and safety through identifying and storing the items used, maintaining the work areas and items, and sustaining the new order through standardization and employee training.
Level One - Unlock Your Career in Manufacturing - SampleAnanth Palaniappan
Many studies in India state that more than 90% of engineers are not readily employable, resulting in poor understanding of the shop floor, reduced productivity and resulting in poor business performance of the companies.
Level One is a detailed guide on providing induction training to engineers and graduates joining the manufacturing sector in India, which is not covered in any curriculum. This book will help in understanding the fundamentals of various functions, job responsibilities, various tools and techniques, MIS reports and the analysis to be done, thus serving as an Induction Kit for new employees.
Visit www.levelone.co.in to read about the book and order
Buy this book here: https://notionpress.com/read/level-one
To become a Lean enterprise, office activities must fully support shop-floor manufacturing operations to eliminate waste. The adoption of 5S throughout all office functions is the first step to increase efficiency.
This presentation provides a blueprint for building a Lean foundation for your office. You will learn how to mobilize and align your management team to launch or improve 5S in your office. The presentation covers 5S and Visual Management key concepts, best practices, step-by-step implementation guidance, and how to kick-start 5S in your organization to achieve sustainable world-class excellence.
LEARNING OBJECTIVES:
1. Understand the benefits of working in a clean and neat environment
2. Identify waste in the office
3. Define the 5S principles, and identify visual tools
4. Explain how to apply the 5S principles and visual tools to enhance office organization
5. Learn how to kick start a 5S initiative
6. Define the critical success factors for 5S implementation
CONTENTS:
Introduction & Overview
5S Lays the Foundation for a Lean Enterprise
5S Helps to Eliminate Waste
What is 5S?
Benefits of 5S
5S Principles - Step by Step
How to Conduct a Red Tagging Exercise
Creating a Visual Office
5S Applications
5S Implementation
Starting & Launching a 5S Initiative
5S Audit System & Maturity Levels
5S & Kaizen
Supporting Lean Tools for 5S
Critical Success Factors
To download this complete presentation, please go to: http://www.oeconsulting.com.sg
This document provides an overview of Module 1 of an MP407 Total Quality Management course. It includes:
1) An introduction to the need for quality and the evolution and definition of quality.
2) An overview of the basic concepts of total quality management (TQM), including the definition of TQM and TQM framework.
3) A discussion of the contributions of quality experts such as Deming, Juran, and Crosby, and barriers to implementing TQM.
The document outlines the key topics that will be covered in Module 1 of the course on total quality management.
The Training is a 1 day course covering impartation knowledge of Kaizen and its associated Tools and; -application of Lean concepts to lead Kaizen Workshop/s with Innovation Projects for Change in a World Class Manufacturing Environment.
This training aims to impart a systematic review on all the critical aspects of Lean use to; lead Kaizen workshop and presentation using Standardize Kaizen form and methodology with;
Innovation to be competitive in the Global Business Environment.
COURSE CONTENT
Kaizen, its definition and Principles
Kaizen definition, Innovation Definition
Kaizen vs Innovation
Characteristics of a Lean Factory
Cellular Factory Layout
Multi-skilled Operators
6S and Visual Control
Kanban and Supermarkets
Rapid Changeover
Total Quality Approach
Right-sized, flexible equipment
Water Strider
Moving Production Lines
Total Productive Maintenance
Continuous Improvement
The 3 Pillars of Kaizen
1. 6S (5+1S) Housekeeping
2. Waste Elimination
- Types of Waste CLOSEDMITT
- Valued-added vs Non-value
added
3. Standard Operation
Three factors that accounts the 3 Pillars Activities.
1. Visual management,
2. The role of the supervisor,
3. Importance of training and
creating a learning
organization.
Innovation & Workshop Projects
Types of Innovation in Kaizen. Why Innovation?
Degree of Innovation-the act of creating new products,
processes, ideas, etc...
Examples of Types of Innovation
Innovating Process using Typical Kaizen concepts (Lean
methods)
Phase 1: Pre-Planning for Innovation
Phase 2: Execution - Innovation Week
Role of Leader, Facilitator, Participant in Innovation
Projects
Innovation Projects Implementation using Kaizen Forms for:
Daily and Weekly Report Outs
Follow-up for further Innovation
The document summarizes a Kaizen event focused on applying the 5S methodology to organize and clean up a workplace. It provides background on 5S, describing the five steps as Sort, Set In Order, Shine, Standardize, and Sustain. Before and after photos show the transformation of the workspace, which was cluttered and disorganized before but became tidy and well-labeled. Testimonials from team members Roxanne Newlin and Sharon Holsinger praise the improved efficiency, safety, and productivity resulting from the collaborative Kaizen project.
The document provides an overview of a study conducted on implementing 5S principles in the clothing and textile industries in South Africa. It discusses challenges like waste, inefficiencies and health issues currently experienced. The study used qualitative methods like observations and discussions. It found that implementing 5S led to reductions in waste costs up to 80% at a textile company over 3 years. Common barriers to 5S implementation identified were lack of management commitment, understanding and employee involvement. The document concludes 5S implementation improved organization and productivity if properly maintained.
Juran's Trilogy is a methodology for managing quality that involves three processes: quality planning, quality control, and quality improvement. It aims to continuously improve quality in all aspects of an organization. The methodology allows companies to understand relationships between each stage and use quality tools to implement the stages. Strengths include searching for continuous improvement and the ability to restart if goals are not met. Weaknesses include needing trained staff and focusing on processes rather than the workforce. Kaizen is a Japanese philosophy of continuous incremental improvement involving maintenance and improvement activities. It differs from innovation by aiming for small process improvements rather than dramatic changes. Business process reengineering fundamentally rethinks and radically redesigns processes to achieve dramatic performance improvements in areas like costs
Total Productive Maintenance - A Systematic Reviewijsrd.com
TPM is an effective tool and a practical technique, which is aimed at maximizing the effectiveness of the facility by minimizing the downtime of machine, production losses and the material, production losses that occurs during the continuous production process. This also increase the working efficiency and productivity of the employee and a positive inclination is registered in the overall environment of a company. This paper presents the literature review of total productive maintenance which is a positive approach for solving the manufacturing problem, also gives the objective of TPM, a detail about a six big losses, 8 pillar of TPM also give the tool used for improvement, implementation stages, methodology for calculating the overall equipment efficiency and also give the direct and indirect benefits of TPM. The aim of this paper is to study the TPM concept and its implementation program which gives a successful improvement in overall equipment efficiency.
Work study techniques like method study and work measurement can be used to improve productivity by reducing excess work content and ineffective time. The key steps involve observing current work processes, analyzing for unnecessary tasks or motions, developing more efficient methods, and setting standard times to measure productivity. Implementing work study can lead to greater output, better quality, and higher productivity through systematic analysis and improvement of work methods.
1. The document discusses work measurement and work study techniques, which aim to improve work efficiency by establishing standard times for jobs and eliminating ineffective time.
2. Key aspects covered include definitions of work measurement, method study, and time study. Objectives, basic procedures, scope and advantages are provided for each technique.
3. Human factors that can impact work are also discussed, along with the relationship between management and workers in work study and how effective communication is important for success.
This document provides an overview of quality management principles and standards. It discusses key quality concepts like quality control, the eight dimensions of quality, ISO 9000 and 14000 quality standards, Kaizen continuous improvement process, and Total Quality Management. The goal of quality management systems is to ensure customer satisfaction through consistent adherence to quality standards and continual process improvement at all levels of an organization.
5-S was developed in Japan, is the name of a workplace organization method that uses a list of five Japanese words: Seiri, Seiton, Seiso, Seiketsu, Shitsuke. 5-S’s are basic in establishing norms for effective performance as well as is a technique to ensure incremental improvement.
MPROVING WORKING ENVIRONMENT AND PRODUCTIVITY OF A SEWING FLOOR IN RMG INDUSTRYSharif Mrh
This document is an assignment submitted by 5 students from Shanto-Mariam University of Creative Technology in Dhaka, Bangladesh. The assignment focuses on implementing Kaizen techniques to improve the working environment and productivity of a sewing floor in an RMG (ready-made garments) industry. Key points:
- Kaizen techniques like 5S, reducing work in progress, and identifying/addressing top defects were implemented.
- Defects decreased from 134 to 51 per hundred units and work in progress decreased from 152 to 106 after implementation.
- Problems identified included low employee motivation and turnover. Recommendations included training and incentive plans.
- In conclusion, Kaizen implementation significantly improved productivity,
A throughput bulletin for Texport Syndicate, post vsmSourav Kumar
This document summarizes an apparel internship opportunity at Texport Syndicate India Limited in Bangalore. It provides details about the company's production facilities, processes, and departments involved in apparel manufacturing. It then describes a proposed lean manufacturing project to map the value stream and optimize the production process for a specific kids' plaid shirt style being manufactured, with the goal of reducing costs while ensuring efficient resource usage and throughput.
Work study might be the paramount methodology to improve productivity in the ...Alexander Decker
This document discusses how introducing work study principles could significantly improve productivity in the apparel industries of Bangladesh. It defines work study as a management technique that establishes standard times for tasks and determines the most efficient methods for completing tasks. The document argues that as manual work is prevalent in Bangladesh's apparel industry, work study would be the best systematic methodology for analyzing current work methods and setting standard times to maximize efficiency and productivity. It provides examples of how work study has helped other industries improve productivity by redesigning work processes and balancing production lines. The document concludes that work study is the paramount methodology for examining work methods and improving productivity in Bangladesh's apparel industry.
Work study involves analyzing work methods and equipment used to perform jobs in order to design optimal work methods and standardize proposed methods. It aims to systematically analyze current work processes to develop more efficient methods that improve productivity and reduce costs. Key techniques of work study include method study, work measurement, time study, and motion study. The overall goal is to establish performance standards and design work systems that maximize efficiency and minimize waste of resources.
A presentation on The Kaizen Pholosophy, a well known workplace management philosophy originated in Japan.
The application of this philosophy has led to the success of several companies like Toyota and Canon.
KAIZEN: A Lean Manufacturing Techniquevivatechijri
Now-a-days the ultimate goal of all industries is to enhance productivity through simplified system
and incremental improvements by applying some modern available techniques. At present, many manufacturing
companies are facing problems such as high quality rejection, high inventories, high lead time, high costs of
production, and inability to cope with customer orders. By implementing and practicing the lean production
system many problems can be solved without employing high-tech and high-touch approaches but by involving
people on the shop floor in Kaizen activities. For continuous improvement in an organization, Japanese
philosophy Kaizen is very popular. Flawless concepts of Kaizen methodology and proper implementation of tools
can lead to a successful kaizen program in a company. Kaizen is one of the powerful tools of lean manufacturing.
Kaizen refers to continuous improvement in performance, cost and quality. Kaizen ensures that manufacturing
processes become leaner and fitter, but eliminate waste (problem) where value is added. The main objective of
this paper is to provide a background on kaizen, present an overview of kaizen concepts that are used to transform
a company into a high performing lean enterprise.
The 5S methodology is a workplace organization method originally developed in Japan that consists of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. The methodology involves sorting, setting in order, shining, standardizing, and sustaining a clean, orderly work environment. It is designed to increase efficiency, quality, and safety through identifying and storing the items used, maintaining the work areas and items, and sustaining the new order through standardization and employee training.
Level One - Unlock Your Career in Manufacturing - SampleAnanth Palaniappan
Many studies in India state that more than 90% of engineers are not readily employable, resulting in poor understanding of the shop floor, reduced productivity and resulting in poor business performance of the companies.
Level One is a detailed guide on providing induction training to engineers and graduates joining the manufacturing sector in India, which is not covered in any curriculum. This book will help in understanding the fundamentals of various functions, job responsibilities, various tools and techniques, MIS reports and the analysis to be done, thus serving as an Induction Kit for new employees.
Visit www.levelone.co.in to read about the book and order
Buy this book here: https://notionpress.com/read/level-one
To become a Lean enterprise, office activities must fully support shop-floor manufacturing operations to eliminate waste. The adoption of 5S throughout all office functions is the first step to increase efficiency.
This presentation provides a blueprint for building a Lean foundation for your office. You will learn how to mobilize and align your management team to launch or improve 5S in your office. The presentation covers 5S and Visual Management key concepts, best practices, step-by-step implementation guidance, and how to kick-start 5S in your organization to achieve sustainable world-class excellence.
LEARNING OBJECTIVES:
1. Understand the benefits of working in a clean and neat environment
2. Identify waste in the office
3. Define the 5S principles, and identify visual tools
4. Explain how to apply the 5S principles and visual tools to enhance office organization
5. Learn how to kick start a 5S initiative
6. Define the critical success factors for 5S implementation
CONTENTS:
Introduction & Overview
5S Lays the Foundation for a Lean Enterprise
5S Helps to Eliminate Waste
What is 5S?
Benefits of 5S
5S Principles - Step by Step
How to Conduct a Red Tagging Exercise
Creating a Visual Office
5S Applications
5S Implementation
Starting & Launching a 5S Initiative
5S Audit System & Maturity Levels
5S & Kaizen
Supporting Lean Tools for 5S
Critical Success Factors
To download this complete presentation, please go to: http://www.oeconsulting.com.sg
This document provides an overview of Module 1 of an MP407 Total Quality Management course. It includes:
1) An introduction to the need for quality and the evolution and definition of quality.
2) An overview of the basic concepts of total quality management (TQM), including the definition of TQM and TQM framework.
3) A discussion of the contributions of quality experts such as Deming, Juran, and Crosby, and barriers to implementing TQM.
The document outlines the key topics that will be covered in Module 1 of the course on total quality management.
The Training is a 1 day course covering impartation knowledge of Kaizen and its associated Tools and; -application of Lean concepts to lead Kaizen Workshop/s with Innovation Projects for Change in a World Class Manufacturing Environment.
This training aims to impart a systematic review on all the critical aspects of Lean use to; lead Kaizen workshop and presentation using Standardize Kaizen form and methodology with;
Innovation to be competitive in the Global Business Environment.
COURSE CONTENT
Kaizen, its definition and Principles
Kaizen definition, Innovation Definition
Kaizen vs Innovation
Characteristics of a Lean Factory
Cellular Factory Layout
Multi-skilled Operators
6S and Visual Control
Kanban and Supermarkets
Rapid Changeover
Total Quality Approach
Right-sized, flexible equipment
Water Strider
Moving Production Lines
Total Productive Maintenance
Continuous Improvement
The 3 Pillars of Kaizen
1. 6S (5+1S) Housekeeping
2. Waste Elimination
- Types of Waste CLOSEDMITT
- Valued-added vs Non-value
added
3. Standard Operation
Three factors that accounts the 3 Pillars Activities.
1. Visual management,
2. The role of the supervisor,
3. Importance of training and
creating a learning
organization.
Innovation & Workshop Projects
Types of Innovation in Kaizen. Why Innovation?
Degree of Innovation-the act of creating new products,
processes, ideas, etc...
Examples of Types of Innovation
Innovating Process using Typical Kaizen concepts (Lean
methods)
Phase 1: Pre-Planning for Innovation
Phase 2: Execution - Innovation Week
Role of Leader, Facilitator, Participant in Innovation
Projects
Innovation Projects Implementation using Kaizen Forms for:
Daily and Weekly Report Outs
Follow-up for further Innovation
The document summarizes a Kaizen event focused on applying the 5S methodology to organize and clean up a workplace. It provides background on 5S, describing the five steps as Sort, Set In Order, Shine, Standardize, and Sustain. Before and after photos show the transformation of the workspace, which was cluttered and disorganized before but became tidy and well-labeled. Testimonials from team members Roxanne Newlin and Sharon Holsinger praise the improved efficiency, safety, and productivity resulting from the collaborative Kaizen project.
The document provides an overview of a study conducted on implementing 5S principles in the clothing and textile industries in South Africa. It discusses challenges like waste, inefficiencies and health issues currently experienced. The study used qualitative methods like observations and discussions. It found that implementing 5S led to reductions in waste costs up to 80% at a textile company over 3 years. Common barriers to 5S implementation identified were lack of management commitment, understanding and employee involvement. The document concludes 5S implementation improved organization and productivity if properly maintained.
Juran's Trilogy is a methodology for managing quality that involves three processes: quality planning, quality control, and quality improvement. It aims to continuously improve quality in all aspects of an organization. The methodology allows companies to understand relationships between each stage and use quality tools to implement the stages. Strengths include searching for continuous improvement and the ability to restart if goals are not met. Weaknesses include needing trained staff and focusing on processes rather than the workforce. Kaizen is a Japanese philosophy of continuous incremental improvement involving maintenance and improvement activities. It differs from innovation by aiming for small process improvements rather than dramatic changes. Business process reengineering fundamentally rethinks and radically redesigns processes to achieve dramatic performance improvements in areas like costs
Total Productive Maintenance - A Systematic Reviewijsrd.com
TPM is an effective tool and a practical technique, which is aimed at maximizing the effectiveness of the facility by minimizing the downtime of machine, production losses and the material, production losses that occurs during the continuous production process. This also increase the working efficiency and productivity of the employee and a positive inclination is registered in the overall environment of a company. This paper presents the literature review of total productive maintenance which is a positive approach for solving the manufacturing problem, also gives the objective of TPM, a detail about a six big losses, 8 pillar of TPM also give the tool used for improvement, implementation stages, methodology for calculating the overall equipment efficiency and also give the direct and indirect benefits of TPM. The aim of this paper is to study the TPM concept and its implementation program which gives a successful improvement in overall equipment efficiency.
Work study techniques like method study and work measurement can be used to improve productivity by reducing excess work content and ineffective time. The key steps involve observing current work processes, analyzing for unnecessary tasks or motions, developing more efficient methods, and setting standard times to measure productivity. Implementing work study can lead to greater output, better quality, and higher productivity through systematic analysis and improvement of work methods.
1. The document discusses work measurement and work study techniques, which aim to improve work efficiency by establishing standard times for jobs and eliminating ineffective time.
2. Key aspects covered include definitions of work measurement, method study, and time study. Objectives, basic procedures, scope and advantages are provided for each technique.
3. Human factors that can impact work are also discussed, along with the relationship between management and workers in work study and how effective communication is important for success.
This document provides an overview of quality management principles and standards. It discusses key quality concepts like quality control, the eight dimensions of quality, ISO 9000 and 14000 quality standards, Kaizen continuous improvement process, and Total Quality Management. The goal of quality management systems is to ensure customer satisfaction through consistent adherence to quality standards and continual process improvement at all levels of an organization.
5-S was developed in Japan, is the name of a workplace organization method that uses a list of five Japanese words: Seiri, Seiton, Seiso, Seiketsu, Shitsuke. 5-S’s are basic in establishing norms for effective performance as well as is a technique to ensure incremental improvement.
MPROVING WORKING ENVIRONMENT AND PRODUCTIVITY OF A SEWING FLOOR IN RMG INDUSTRYSharif Mrh
This document is an assignment submitted by 5 students from Shanto-Mariam University of Creative Technology in Dhaka, Bangladesh. The assignment focuses on implementing Kaizen techniques to improve the working environment and productivity of a sewing floor in an RMG (ready-made garments) industry. Key points:
- Kaizen techniques like 5S, reducing work in progress, and identifying/addressing top defects were implemented.
- Defects decreased from 134 to 51 per hundred units and work in progress decreased from 152 to 106 after implementation.
- Problems identified included low employee motivation and turnover. Recommendations included training and incentive plans.
- In conclusion, Kaizen implementation significantly improved productivity,
A throughput bulletin for Texport Syndicate, post vsmSourav Kumar
This document summarizes an apparel internship opportunity at Texport Syndicate India Limited in Bangalore. It provides details about the company's production facilities, processes, and departments involved in apparel manufacturing. It then describes a proposed lean manufacturing project to map the value stream and optimize the production process for a specific kids' plaid shirt style being manufactured, with the goal of reducing costs while ensuring efficient resource usage and throughput.
Work study might be the paramount methodology to improve productivity in the ...Alexander Decker
This document discusses how introducing work study principles could significantly improve productivity in the apparel industries of Bangladesh. It defines work study as a management technique that establishes standard times for tasks and determines the most efficient methods for completing tasks. The document argues that as manual work is prevalent in Bangladesh's apparel industry, work study would be the best systematic methodology for analyzing current work methods and setting standard times to maximize efficiency and productivity. It provides examples of how work study has helped other industries improve productivity by redesigning work processes and balancing production lines. The document concludes that work study is the paramount methodology for examining work methods and improving productivity in Bangladesh's apparel industry.
Work study involves analyzing work methods and equipment used to perform jobs in order to design optimal work methods and standardize proposed methods. It aims to systematically analyze current work processes to develop more efficient methods that improve productivity and reduce costs. Key techniques of work study include method study, work measurement, time study, and motion study. The overall goal is to establish performance standards and design work systems that maximize efficiency and minimize waste of resources.
Proposta tesi di laurea SUPSI su Comunicare wikipediaIolanda Pensa
Comunicare Wikipedia
Una campagna di comunicazione integrata per aumentare il numero di contributori di Wikipedia coinvolgendo i frequentatori della biblioteche.
L’obiettivo di questa proposta è di coinvolgere uno studente di comunicazione visiva nel preparare una campagna di comunicazione integrata che si indirizza specificatamente alle biblioteche, creando un welcome kit destinato a potenziali contributori di Wikipedia. Il welcome kit può include una serie di materiali analogici e digitali pensati per persone che non sanno che si può contribuire a Wikipedia e per persone che sanno che si può contribuire ma non sanno su cosa contribuire (es. poster, segnalibro, un sito con landing page per i nuovi contributori…).
Attualmente gli strumenti di comunicazione di Wikipedia sono limitatissimi (alcuni volantini e video-tutorial) e non sono mai state fatte campagne di comunicazione sistematiche su un territorio. Non c’è bisogno di comunicare Wikipedia perché è la più nota e discussa enciclopedia online con 500 milioni di persone che la leggono; il problema è l’esiguo numero di persone (stimati 70’000 contributori attivi) che la scrivono. Chiunque può contribuire a Wikipedia aggiungendo un paragrafo o un’immagine, correggendo un errore o traducendo un articolo, ma pochi sanno che lo possono fare o sanno quanto importante e prezioso può essere il loro contributo.
La tesi è un lavoro originale non previsto all’interno di nessun progetto di ricerca attualmente in corso alla SUPSI ma collegato ai temi delle ricerche “MobileA2K”, “Il paesaggio culturale alpino su Wikipedia”, “Swiss Foundations and Open Licenses”, “Wikipedia Primary School”. È altamente probabile che le associazioni Wikimedia CH e Wikimedia Italia (che sostengono Wikipedia in Italia e Svizzera) siano interessate a realizzare la campagna di comunicazione nelle 1300 biblioteche della Lombardia e nelle circa 70 biblioteche del Ticino. È importante menzionare che i contributori a Wikipedia del Ticino sono pochissimi.
Proposta di tesi, SUPSI, 24 marzo 2015
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Analysis of Productivity Improvement And Safety Measures By 5-S Technique
1. Sandip K. Tikale Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 3, ( Part -3) March 2015, pp.102-106
www.ijera.com 102 | P a g e
Analysis of Productivity Improvement And Safety Measures By
5-S Technique
Sandip K. Tikale*, Deepa Hadge **
*(Department of Mechanical Engineering, RTMN University, Nagpur-440009)
**(Department of Mechanical Engineering, RTMN University, Nagpur-440009)
ABSTRACT:
We provided some vast literature on the implementation of 5S in any industry. This strategy involves the study and change
in the work place of a manufacturing industry post implementation of 5S. This strategy helps in minimizing the time of
manufacturing and also increases the area of work place. From the implementation of 5S we improve the some most
useful things such as:
• Improves safety and ergonomics • Promotes flow • Reduces searching
• Reduces unplanned downtime • Improve quality • Encourages visual control
• Enhances teamwork • Improves productivity • Eliminates distractions
• Reduces inventory and space • Exposes problems • Tackles waste
• Instills the discipline to follow standard work • Enhances self-management
The main objective of this study is to assess the implementation of 5S and development of the 5S Activity
Checklist in manufacturing companies. The scope for this study covers the following areas: identifying
problems, looking into critical success factors, their outcomes and recommendations. In addition, factors that
may act as constraints to the implementation of the 5S activity and possible solutions for the industries are also
identified through observation and evaluation of the improved environmental performance. The study is
conducted using a systematic approach with specific software in order to get the most accurate results.
I. INTRODUCTION:
This paper concentrates on the result of study
carried out as part of a research project in developing
and implementing the checklist for the 5S activity in
a manufacturing Industry. From the study
conducted, it is possible that an appropriate and
simple checklist can be derived and implemented but,
it has proved to be rather difficult in getting accurate
results, as certain information is considered as
confidential and therefore companies are not willing
to release their confidential information. This paper is
presented as follows: the first part discusses the
concepts of the 5S,the second part presents the
problems occurred in the manufacturing Industry, the
third part gives a description of the methodology
employed in gaining the relevant information
concerning the industries studied and Finally, the
conclusion and references.
The 5S Practice is a technique used to establish and
maintain quality environment in an organization. The
original concept was developed by Osada in the early
1980s. 5S is a strategy that delivers results by a
systematic approach of planning and organizing the
activities. 5S is a philosophy rooted from Japan and
branched into other countries. 5S is an acronym for the
following Japanese terms:
SEIRI [Sort]
SEIRON [Set in order]
SEISO [Shine]
SEIKETSU [Standardize]
SHITSUKE [Sustain]
In a manufacturing environment, the 5S in practice
can bring in results that could considerably raise the
environmental performance in line with the improved
housekeeping and health & safety. The 5S practice in
theory involves straightforward steps which lead to
continuous improvements.
II. CONCEPT:
Modern management in the company is not only
the quality management system based on the ISO
series 9000:2000 standards, but pursuit to the
continuous improvement, so this is the philosophy of
the Total Quality Management [1]. In the frames of
implementation of the Total Quality Management on
the operating level more and more popular becomes
the idea of so called 5S. The 5S method begins each
programme of improvement. It is the tool for helping
the analysis of processes running on the workplace.
The 5S is the methodology of creation and
maintaining well organized, clean, high effective and
high quality workplace. Its result is the effective
organization of the workplace, reduction of work’s
RESEARCH ARTICLE OPEN ACCESS
2. Sandip K. Tikale Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 3, ( Part -3) March 2015, pp.102-106
www.ijera.com 103 | P a g e
environment, elimination of losses connected with
failures and breaks, improvement of the quality and
safety of work [2-4].
The 5Ss
Sort (Seiri)
• No unnecessary items at the workplace: “When in
doubt, throw it out!”
Set in Order (Seiton)
• Anyone can instantly find, take, and return any
needed item:“A place for everything, and everything
in its place”
Shine (Seiso)
• Deviations become visual by cleaning: “Cleaning
= inspection; Cleaning with meaning”
Standardize (Seiketsu)
• Visualize the 5S standards in the workplace:
“Make the best way the easiest way”
Sustain (Shitsuke)
• Everybody follows the standard until we have a
better one:“Stick to it!”
III. IDENTIFICATION OF PROBLEMS:
In many manufacturing industry there are so
many problems related to productivity. It is major
problem in industry because it affects industrial
growth. In this industry there are so many problems
which affect their productivity and production. The
following are the problems found in that industry:-
3.1 No Painting shop: - There is no separate
paint shop. Thus painting is done in free
space. The paint particles get spread in all
over the shop.
3.2 Improper handling of material: - In this
industry improper material handling by
workers take place, due to which chances of
accident increases.
3.3 Improper inventory of materials: - There is
no specific space for raw materials and
finished products. Due to this workers face
much problem to find proper material. It
increases production time.
3.4 Less safety measures: - In this industry, the
proper safety equipments are not available.
So that it increases accidents to them.
3.5 Environmental hazardous: - In the industry
some machining operation is done in open
space like grinding, painting etc. Due to this
particles get spread in environment because
of it environment get hazard.
IV. METHODOLOGY:
The researcher will first figure out the issues
which exist and guild the personnel of the company
to understand what 5S tools are, then apply 5S
concepts to rearrange the items utilizing all of
employees Bajaj Steel Industries Limited. The
purpose of this study was to assist Bajaj Steel
Industry to improve the process flow with 5S
methods in order to reduce possible wastes and
enhance the efficiency of operations so that Bajaj
Steel Industry can reduce costs. Since Bajaj Steel
Industry has never done anything with 5S, and no one
in the company knows what 5S and how it can help
the company to improve the working environment,
this study has provide the evidence that 5S is a great
way to assist this organization. 5S provides a method
to rearrange the layout and enhance the discipline.
This study focused on how to use 5S in each step to
help Bajaj Steel Industry manufacturing company to
rearrange the workplace and improve the efficiency.
So we suggest to that Industry to use 5S and we will
describe each step and how 5S works entirely in the
company.
5S Systematization:
5S states that:
SEIRI (sorting and disposing the unnecessary
items). Deals with sorting all the tools,
materials and other equipment in the
workplace. Important equipment is stored
accordingly, which reduces the hazards at the
work place.
SEITON (everything is set in order, provide a
place for everything). Identifies the need of
the worker. Tools, materials and other
equipment should be arranged systematically
for quick access and movement.
SEISO (shining, cleaning, removal of waste
and dust) Point outs the need and necessity of
clean and neat work place. Cleaning should
become a daily activity. Work place should
be cleaned at regular intervals (generally at
the end of the shift or once in 3hours). Every
tool and equipment should be restored at
their own places after their use.
SEIKETSU (consistent and standardized
work environment with unique rules of
organization and storage along with
cleanliness). Everyone should know his or
her responsibility. Cleaning should become a
part of regular work routines. This helps in
having a good control over the production.
SHITSUKE (Sustain, realization of the above
set of rules in order). Maintain these standards
continuously for years.
3. Sandip K. Tikale Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 3, ( Part -3) March 2015, pp.102-106
www.ijera.com 104 | P a g e
Implementing 5S:
Implementing 5S should begin from educating
the workers about 5S and its importance. It is
mandatory that every worker should understand the
need of 5S and its advantages. Workers should be
provided with an example for all the 5S’s, which
makes i t easy to understand. It is very important to
understand the fact that this methodology do not refer
only for the production team but also refers to stores
(warehouse) and other office teams. It is better to
supply a 5S pocket guide to the workers such that they
could clarify their doubts by reading it.
1 S – Sort:
Eliminate unnecessary materials, tools, parts,
equipments. Sorting identifies necessary information for
the realization of tasks. Sorting eliminates the waste
raw materials, nonconforming stock, and damaged
tools. Keep only necessary items and eliminate what
is not required. It improves the efficiency of searching
and collecting items, reduces the running time of
operation. Sort is the concept helps the company to
keep everything they need and throw non-use items
away Based on Sort concept, a company collects all
items that it has now and determines whether or not
it will be used, distinguishing the items into two
different categories: used and non-used. In Bajaj
Steel Industry, they have several places that the
owner uses for setting all welding. Grinding and
painting. Yet, Industry never has a place for setting
specific shop for painting and raw material is placed
anywhere due to this product should be damaged. By
sort step, Industry looked at each inventory place
and confirmed what the company needed, then what
they did not need, and what was broken.
Implementing 1S rule:
1) On the first stage one should be able to answer
the control questions:
Does an unnecessary thing create the
problem in work area?
Does unnecessary odds and ends of materials
thrown anywhere in the work area?
Do tools and rest of materials of production
are placed on the shop floor?
Are all necessary things sorted, ordered and
retain at their own place?
Are a l measuring tools sequentially kept? On
the basis of answers to the above questions i t is
possible for the assessment of work area in terms of the
1S rule. I f any question answer is yes, i t should
carry out sorting of items, which are in work area.
2) On the second stage one should carry out the
review of all things which are in the work area and
arrange them. According to established sorting it
should execute the elimination of items from work
area, which were unnecessary.
3) To continual usage the 1S rule is the movement of
the Red Tag. It means giving red tag to items, which
operator will make out as useless within his work
area. At the beginning of each month, put a red tag on
every item. During the month, remove the red tag
when item is used. At the end of the month, decide
whether the item with the tag is necessary or not.
2 S – Set in order:
The important thing is visualization of work area
the painting of the floor helps to identify the storage
places of each material or transport ways. The place for
each item should be labeled. Each tool, material,
supply, or piece of equipment should be kept close to
where it will be used - in other words, aligning the
flow path.
Implementing the 2S rule:
It means items must be placed in fixed locations so
that they are easily attainable and can be easily used. 2S
rule proceedings:
Make sure that items can be identified by labeling
them properly. Every working method has particular
type of order. Identify and filter it. Use lean thinking
to make things faster.
Reduce preparation time for tool setting.
Reduce waiting time for parts, materials,
papers and files
Reducing processing time and cycle time by
Improving the plant layout of work area.
Time and strength spent on looking for jigs,
Fixture tools etc.
Searching for files and information in
computers.
Labels are attached so that items can be
recognized.
At a glance and clear.
3S – Shine
Regular cleaning permits to identify and to eliminate
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sources of mess and to maintain the clean workplaces.
During cleaning machine, work area and shop floor,
sources of light, current information, cleanliness of
path are checked. Operator should take care about
personal maintenance and tidiness.
Implementing 3S rule:
The first step of 3S rule is improving the
workplace, daily follow-up cleaning is necessary in
order to sustain this improvement. Cleanliness is helpful
to notice damages on equipment such as cracks,
breakage and misalignment.
4S – Standardize:
Standards should be worked out and implemented in
the work place. Management should pass instructions
in order to set the work place in order. The
Instructions should be clear and easily understandable
to workers. All the workers in the shop floor should be
involved in this activity; the workers group knows
specificity of their own activities and process of
elaboration along with the usage gives them the
possibility of understanding the importance of each
aspect of the operation. The aim of the easy access of
the obligatory standards for constant and visible places
should be assured.
It should be assumed that standards are not only
being implemented in typical operational processes like
movement of materials, production, maintenance and
sorting, but also in administrative processes like Book-
keeping, HRM(human resource management),
customer service and any other services.
5S – Sustain:
The principle is to establish the maintenance of a
clean environment as an ongoing process for ever. This
increases the consciousness if the workers and decreases
the number of non-confirming products and defective
products. This process also increases the internal
communication and human relations in the
organization.
It is also essential to understand the need and
importance of the inspections for 5S. The inspections are
executed with the help of Check list prepared on the
basis of the radar charts of 5S. This also helps in
estimating the work place. The inspection of the
realization of 5S standards is executed once in a month
by the team.
5s Approach In Industry:
The 5S methodology depends upon the capacity of
creating and maintaining a well organized, clean,
effective and high quality work place. Our research
was carried out in a manufacturing company of the
metal doors. In the first phase of research we executed
the selection of things in the production process of the
work place. We introduced 5S methodology to the
workers on the shop floor and carried out a questionnaire
for them. After that all the 5 rules of the 5S has been
implemented on the shop floor in a systematic order. We
appointed one of the workers as a person responsible for
the implementation of 5S for that department and so
with the other departments of the industry. This resulted in
great changes on the shop floor.
Fig (I): changes in the shop floor before and after
V. SOLUTION
5.1) Making Separate Painting Shop
These alternatives include that to make a
separate painting shop. Separate painting shop means
that the suspended paint particles have no chance
produce obstacles in other working shops of industry.
It will provide that the machining is in machining
shop, assembly in assembly shop and painting in
painting shop. So those have not any effects of paint
particles in machining and assembly shop. Therefore
workers can work comfortably. So using this option,
we are removing problems that are 1) stoppage of
work 2) bad working efficiency 3) hazardous
environment in machining and assembly shop. But
still there is bad working condition in painting shop.
The suspended particles are hazardous for workers in
paint shop. This problem will solve by allowing
exhaust blower at the top of paint shop. But the
handling time of moving product from assembly to
paint shop is increasing and again there is large
investment in making separate paint shop. So try third
alternative.
5.2) Making Partition for Painting Place And
Allowing Exhaust Blower At The Top
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In that we are making partition where the
painting takes place and utilization of exhaust blower
at the top of painting place to remove the suspended
paint particles. So that the suspended paint particles
will exhaust at a time of painting and there will be no
chance to spread paint particles. Due to this we will
able to make clean whole environment of industry.
VI. ADVANTAGES:
The advantages from implementing the 5S
rules:
1 S:
Process improvement by costs reduction,
Stock decreasing,
Better usage of the working area,
Prevention of losing tools.
2 S:
Process improvement (increasing of
effectiveness and efficiency),
shortening of the time of seeking necessary
things,
Safety improvement.
3 S:
Increasing of machines efficiency,
Maintenance the cleanness of devices,
Maintenance and improvement of the
machines efficiency,
Maintenance the clean workplace, easy to
check,
Quick informing about damages (potential
sources of damages),
Improvement of the work environment.
Elimination of the accidents reasons.
4 S:
Safety increasing and reduction of the
industry pollution,
Working out the procedures defining the
course of processes.
5 S:
Increasing of the awareness and morale,
Decreasing of mistakes quantity resulting
from the inattention,
Proceedings according to decisions,
Improvement of the internal communication
processes,
Improvement of the inter-human relations.
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