5s activity roadmap 28 june_2011
TRANSCRIPT
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Sh
ee
t
Me
tal_Ben
ding
Inco
ming
Inspec
tion
Mach
ining
Ma
ine
nance
Bo
ttom
Ro
ller
Sec
tion
-Ass
ly
Mec
h.
/Elec
t.Ass
ly
July
Aug.
Sr. No. Activity
5.1 Restructuring of 5S Orgn. Structure.
5.1.1
Restructuring of Steering committee
and nomination of 5S Champion &
Facilitators.
5.1.2 Zone formation / Zone restructuring
5.1.3 Provision of 5S Visual ImplementationDisplay Boards.
5.2.1Development of system for 1S
implementation.
5.3.1 1S Training of all members.
5.4.1 1S implementation at all teams
5.5.1Progress review of 1S implementation
level.
5.6.1 1S audit by Kaushal Associates.
5.2.2Development of system for 2S
implementation
5.3.2 2S Training of all members
5.4.2 2S implementation at all teams
5.5.2Progress review of 2S implementation
level
5.6.2 2S audit by Kaushal Associates.
5.2.3Development of system for 3S
implementation.
5.3.3 3S Training of all memebers
5.4.3 3S implementation at all teams
5.5.3Progress review of 3S implementation
level
5.6.3 3S audit by Kaushal Associates
5.7 Sustenance of 1S / 2S / 3S system
5.84S - Standardisation of good practices
followed
July. 1st
Week
AD
AD
AD
July. 1
st
Week
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Heads
toc
k/
Foo
tsto
ckAss
ly
Laser
Cu
tting
Welding
Stores
Raw
Mate
ria
lStores
Finish
Goo
ds
Stores
Pac
king
ShotB
las
ting
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Sh
ee
t
Me
tal_Ben
ding
Inco
ming
Inspec
tion
Packing
Area
Ca
libration
La
b.
Managem
en
tOffice
IMS&SQEOffice
Mac
hining
Ma
intenance
Nov. Dec.
Sr. No. Activity
5.1 Restructuring of 5S Orgn. Structure.
5.1.1
Restructuring of Steering committee
and nomination of 5S Champion &
Facilitators.
5.1.2 Zone formation / Zone restructuring
5.1.3 Provision of 5S Visual ImplementationDisplay Boards.
5.2.1Development of system for 1S
implementation.
5.3.1 1S Training of all members.
5.4.1 1S implementation at all teams
5.5.1Progress review of 1S implementation
level.
5.6.1 1S audit by Kaushal Associates.
5.2.2 Development of system for 2Simplementation
5.3.2 2S Training of all members
5.4.2 2S implementation at all teams
5.5.2Progress review of 2S implementation
level
5.6.2 2S audit by Kaushal Associates.
5.2.3Development of system for 3S
implementation.
5.3.3 3S Training of all members
5.4.3 3S implementation at all teams
5.5.3Progress review of 3S implementation
level5.6.3 3S audit by Kaushal Associates
5.7 Sustenance of 1S / 2S / 3S system
5.84S - Standardization of good practices
followed
3
4
1
1
2
2
Sept. Oct. Nov.
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Bo
ttom
Ro
ller
Sec
tion
-Ass
ly
Pac
king
Mec
h.
/E
lec
t.Ass
ly
Heads
toc
k/
Foo
tsto
ckAss
ly
Pow
der
Coa
ting
Laser
Cu
tting
Welding
ShotB
las
ting
Stores
Raw
Mate
ria
lStores
Finish
Goo
ds
Stores
Pla
ting
Jan. Mar. May Jul
4
Aug.
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3
4 3
4
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Jun
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Apr.Feb.
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Departmen
t
Shee
t
Me
tal_Ben
ding
Incom
ing
Inspec
tion
Mac
hining
Ma
inenance
Bo
ttom
Ro
ller
Sec
tion-
Ass
ly
Pac
king
Mec
h.
/Elec
t.Ass
ly
Hea
ds
toc
k/
Foo
tstoc
kAss
ly
Pow
der
Coa
ting
Laser
Cu
tting
We
lding
Sho
tBlas
ting
Stores
Raw
Ma
teria
lStores
Sr. No. Activity
5.1 Restructuring of 5S Orgn. Structure.
5.1.1 Restructuring of Steering committeeand nomination of 5S Champion &
Facilitators.
5.1.2 Zone formation / Zone restructuring
5.1.3Provision of 5S Visual Implementation
Display Boards.
5.2.1Development of system for 1S
implementation.
5.3.1 1S Training of all members.
5.4.1 1S implementation at all teams
5.5.1Progress review of 1S implementation
level.
5.6.1 1S audit by Kaushal Associates.
5.2.2Development of system for 2S
implementation5.3.2 2S Training of all members
5.4.2 2S implementation at all teams
5.5.2Progress review of 2S implementation
level
5.6.2 2S audit by Kaushal Associates.
5.2.3Development of system for 3S
implementation.
5.3.3 3S Training of all memebers
5.4.3 3S implementation at all teams
5.5.3Progress review of 3S implementation
level
5.6.3 3S audit by Kaushal Associates
5.7 Sustenance of 1S / 2S / 3S system
5.84S - Standardisation of good practices
followed
April
Oct.
Aug.
July Sept.
Sept. Nov.
Dec.
Jan.
Nov.
March
Roadmap for 5S implementation
Jan.
Feb.
March May
J
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Plating
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Location / Teams / Areas Resp.
S.N.
1Top Management Office
(2nd Floor)5S
2 Sheet Metal_Bending Mr. Arali Pravin 5S
3 Incoming Inspection Mr. Shelar Anand 5S
4 Packing Area Mr. Ajay Kamble 5S
5 IMS & SQA Office Mr. Sachin Pawar 5S
6 Calibration Laboratory Mr. V. Shelke 5S
Machining / Turning Mr. Rao / Mr. Deshpande
Maintenance Mr. Bhandare
Bottom Roller Mr. Pisal
Section - Assly Mr. Arvind Shetty
Mech. / Elect. Assly Mrs. Jyoti Kulkarni
Headstock / Footstock Assly Mr. Sutar
Packing Mr. Ajay Kamble
Powder Coating Mr. Gole Vilas
Laser Cutting Mr. Arali Pravin
Welding Mr. Kondhekar Sagar
Shot Blasting Mr. Arali Pravin
Stores Mr. Shaha
Raw Material Stores Mr. Gavali
Finish Goods Stores
Plating Mr. Jagdale
1S 2S 3S 4S
4S
1S 2S 3S
1S
1S 2S 3S
4S
4S
1S 2S 3S 4S
Roadmap For 5S implementation
Pilot Areas:
Month Aug Sep Oct
Other Additional areas / teams:
Mar Apr
1S 2S
Nov Dec Jan Feb
2S 3S
3S
4S
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Aug Sep Oct
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Sr.
No.Process Area Sub-Process Area
Bending ShopLaser Shop
Welding
Powder Coating
Shot Blasting
HMC
VMC
Tool Room
CNC
Cutting Area
Line
Plating
Section Assly.
Mech. Assly.
Elect. Assly
Head Stock / Foot Stock Assly
Blow Room
6 IED Tool Crib
Workshop & Office
Maint. Stores
Utilities
Incoming Inspection
Product Quality
Calibration & CMM
Meta. Lab.
Sheet metal Quality
B/O stores
R. M. Stores
F.G. Stores
Packing
Canteen
Outside / Peripheral areas
Shop_floor areas
Quality8
Process Wastage
1 Sheet Metal
2 Machining Centre
3 Turning Centre
Bottom Roller
Assembly5
7 Maintenance
Stores & Logistics9
4
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Security & Parking
House-keeping
Garden & internal Road
Scrap Yard
ETPGuest House
Rej. Area - Mech.
Supplier Rej. Area - Sheet metal
13 Assembly Assly. Office
14 Quality Quality office
15 IED Production+ 301 Room + Battiwala office
HR office & ReceiptionMedical & Library Room
House-keeping, Toilets
17 IT IT office & IT Stores
18 Supply Management Office & Stationary Room
19 IMS & VQA Fro. Cabin & IMS office
Office of T. Haegi
Ofice of A. Gharat
Office of T. Gulati
Finance office & company secretary
Record Room
22 R & D R & D Office
23 Project & Facility Project & Facility
Total 23 Areas Total - 55 Sub_Areas
21 Finance
HR & Shop Floor office areas
16 HR
First Floor office areas
Second Floor office areas
20 Top Management
12 Quality
10 HR
11 Facility
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Sr. No. Sub-Process Area July Aug. Sept. Oct. Nov.
1 Bending Shop
2 Incoming Inspection
3 Packing
4 Fro. Cabin & IMS office
5 Office of T. Haegi
6 Maint. Stores
7 R. M. Stores
8 Laser Shop
9 Welding
10 Powder Coating
11 Shot Blasting
12 HMC
13 VMC
14 Tool Room
15 CNC
16 Cutting Area
17 Line
18 Plating
19 Section Assly.20 Mech. Assly.
21 Elect. Assly
22 Head Stock / Foot Stock Assly
23 Blow Room
24 Tool Crib
25 Workshop & Office
26 Utilities
27 Product Quality28 Calibration & CMM
29 Meta. Lab.
30 Sheet metal Quality
31 B/O stores
32 F.G. Stores
Project Name :
Process Wastage Month
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33 Canteen
34 Security & Parking
35 House-keeping
36 Garden & internal Road
37 Scrap Yard38 ETP
39 Guest House
40 Rej. Area - Mech.
41 Supplier Rej. Area - Sheet metal
42 Assly. Office
43 Quality office
44ro uct on+ 301 oom + att waa
45 HR office & Receiption46 Medical & Library Room
47 House-keeping, Toilets
48 IT office & IT Stores
49 Office & Stationary Room
50 Ofice of A. Gharat
51 Office of T . Gulati
52nance o ce company
53 Record Room
54 R & D Office
55 Project & Facility
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Dec.
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DepartmentResponsib
ility
Sheet
Metal
Bending
Incoming
InspectionPacking
Mr.
Haegi's
Office
Calibrat-
ion lab.
IMS
Office
Sr. No. Activity
5.1 Restructuring of 5S Orgn. Structure.
5.1.1Restructuring of Steering committee and
nomination of 5S Champion & Facilitators.
5.1.2 Zone formation / Zone restructuring
5.1.3Provision of 5S Visual Implementation
Display Boards.
5.2.1Development of system for 1S
implementation.
5.3.1 1S Training of all members.
5.4.1 1S implementation at all teams
5.5.1 Progress review of 1S implementation level.
5.6.1 1S audit by Kaushal Associates.
5.2.2Development of system for 2S
implementation
5.3.2 2S Training of all members
5.4.2 2S implementation at all teams
5.5.2 Progress review of 2S implementation level
5.6.2 2S audit by Kaushal Associates.
5.2.3Development of system for 3S
implementation.
5.3.3 3S Training of all memebers
5.4.3 3S implementation at all teams
5.5.3 Progress review of 3S implementation level
5.6.3 3S audit by Kaushal Associates
5.7 Sustenance of 1S / 2S / 3S system
5.84S - Standardisation of good practices
followedNov.
Roadmap for 5S implementation
Aug.
Sept.
Oct.
July
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Remarks
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Project Name
Month July Aug. Sep. Oct. Nov. Dec. Remarks
Activity Respons.
Formation of Steering committee and
nomination of 5S Champion
Team formation for Pilot Areas
Provision of 5S Visual Implementation
Display Boards.
Development of system for 1S
implementation.
5S Training of all members.
1S implementation at all teams
Progress review of 1S implementation level.
1S audit by Kaushal Associates.
Development of system for 2S
implementation
2S implementation at all teams
Progress review of 2S implementation level
2S audit by Kaushal Associates.
Development of system for 3S
implementation.
3S implementation at all teams
Progress review of 3S implementation level
3S audit by Kaushal Associates
Sustenance of 1S / 2S / 3S system by Pilot
Areas
4S - Standardisation of good practices
followed
Identification of other additional areas /
teams in Shop-floor / Office
: 5'S Implementation.
Pilot Areas
1) Sheet Metal Bending, 2) Incoming Inspection,
3) Packing Area, 4) Top Management Office (2nd floor),
5)IMS & SQA office 6) Calibration Lab.
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Location / Teams / Areas Resp.
S.N.
1Top Management Office
(2nd Floor)5S
2 Sheet Metal_Bending Mr. Arali Pravin 5S
3 Incoming Inspection Mr. Shelar Anand 5S
4 Packing Area Mr. Ajay Kamble 5S
5 IMS & SQA Office Mr. Sachin Pawar 5S
6 Calibration Laboratory Mr. V. Shelke 5S
Other Shop-floor areas
Other Office Areas
Other peripheral / outside areas 2S1S
1S 2S 3S
1S 2S 3S
AprNov Dec Jan FebSep Oct
2S 3S
Other Additional areas / teams:
Mar
3S
4S
Roadmap For 5S implementation
Pilot Areas:
Month Aug
4S
1S 2S 3S 4S
1S 2S 3S
1S 2S
4S
1S 2S 3S 4S
4S
1S 2S 3S
1S
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5S
5S4S
Aug Sep Oct
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From To 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 6 3 5 7 `
2 1 8 8
1 1 9 9
12 6 10 15
2 1 16 16
2 1 17 17
5 3 18 20
12 6 21 26
11 5 27 31
13 7 32 38
3 1 39 39
7 4 40 43
15 7 44 5051 52
1 4
Straightening
April
Other Dec.
Shot-Blasting
Work Centre Approach
Bending
WeekSr.
No.Work Centre Qty.
Total Week
Required
Cutting
Grinding
Laser Cutting
Punching
Welding
Other
VMC
HMC
CNC
End of 2012
2013
Remarks
Feb.
April
Aug
Aug
Mar-12 Apr-12 May-12 JFeb-12
S
h
e
e
t
M
e
t
a
l
M
a
c
h
C
u
b
6
M
a
c
h
R
n
d
Assly 13
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6 7 8
eb-13
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From To 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
6 2 5 6
2 1 7 7
1 1 7 7
12 4 8 11
2 1 12 12
2 1 13 13
5 2 14 15
12 4 16 19
11 4 20 23
13 4 24 27
3 1 28 28
7 2 29 30
15 5 31 35
4 1 36 36
4 1 37 37
5 2 38 39
Feb-12
M
a
c
h
R
n
d
A
s
s
e
m
b
l
y
Mar-12 Apr-12 May-12
Apr-12
Jun-12
Jun-12
M
a
c
h
C
u
b
Laser Cutting
Punching
Remarks
Feb-12
Sep-12
Sep-12Section assly &
packaging
Top Arm Assly.
Other
Other
VMC
HMC
CNC
Cutting
Grinding
Welding
Shot-Blasting
Work Centre Approach
Bending
WeekSr.
No.Work Centre Qty.
Total Week
Required
S
h
e
e
t
M
e
t
a
l Straightening
Dep.
1
2
3
4
Mar-12
Other Aug-12
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40 41 42 43 44 45 46 47 48 49 50 51 52
Nov-12Oct-12 Dec-12