LEAN MANUFACTURINGIMPLEMENTATION OF 5 ‘S’

Arvind Ltd.Mysore Road

Bangalore

Campus of Arvind Ltd.

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KNITS DIVISION

It has newly been started and has appointed untrained or semi-trained operators.

Eight teams running with 15-16 workstationsOne 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.

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A SCHEMATIC REPRESENTATION OF A SEWING LINE ON KNITS PRODUCTION FLOOR 0

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Knits Floor : Project Area

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ABOUT 5 ‘S’ 07

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5 ‘S’

SEIRI

SEITON

SEISO SEIKETSU

SHITSUKE

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5 ‘S’

1 ‘S’: SEIRI (SORTING OUT)

2 ‘S’: SEITON (SYSTEMATIC ARRANGEMENT)

Objective

Saving & Recovering SpaceFinding method of Disposal.Finding whose responsibility is to dispose

Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting

What is Involved ?

Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting

Arranging in orderA place for every thing and every useful thing in it’s place.

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5 ‘S’

3 ‘S’: SEISO (SPIC AND SPAN)

4 ‘S’: SEIKETSU (STANDARDIZATION)

Objective

Arranging in orderA place for every thing and every useful thing in it’s place.

Achieving higher productivity and better quality.

What is Involved ?

Clearing the work place / equipmentEnsuring –Tip Top conditionMaking a shine calendar.

Working methodology (procedures and work instructions)Calendars for every activity

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5 ‘S’

5 ‘S’: SHITSUKE (SELF DISCIPLINE)

Objective

Doing it Right first time and every time Sustenance of good practices.Setting of efficient standardsResults should be measureable.

What is Involved ?

Forming the habitTrainingEvery notice board should be updated regularly. Regular evaluation ‘Visual display of standards Increase the transparency levelEasy Induction of New Employee.Clean and Check Standards

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METHODOLOGY Problems Found Evaluation before Implementation Implementation Evaluation After Implementation

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PROBLEMS IDENTIFIED

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Bins not kept at their position and defected pieces lying on

floor unattended

Packaging materials, Unused cartons, carton with rejected

pieces lying on the floor

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.

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2 ‘S’ : Seiton

• 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

No labelling and no listing of items on drawers

Place not defined for the materials

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Dustbin cover open and waste are lying outside the

dustbin

Defect stickers stuck on floor

3 ‘S’ : Sieso

• 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.

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WIP on chair

4 ‘S’ : Sieketsu

• No visual guidance for operators.

• No SOP• No single piece movement

(Variable WIP at different workstations)

• Inappropriate uniform of workers

5 ‘S’ : Shitsuke

• Workers not following workplace discipline

EVALUATION BEFORE IMPLEMENTATION

• Before Implementation.xlsx

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IMPLEMENTATION

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1 ‘S’: SEIRI (SORTING OUT)

SEGREGATE

NEEDED

More Frequently

Keep in middle shelf

Less Frequently

Keep in bottom or top

most shelf

NOT NEEDED

Not Needed At All Discard

Needed But Not Now

Red Tag (With proper

labeling)

Needed But Not Here

Red Tag (With proper

labeling)

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1 ‘S’: SEIRI (SORTING OUT)

STEPS CARRIED OUT

•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.

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Red Tag Area

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Name of the object

Area to which the object belongs

Quantity

Authorized Person to handle

Authorized Person to dispose

Used/Unused

Validity

Method of Disposal

Label to be put on every object in Red Tag Area (fields to be filled as required)

2 ‘S’: SEITON (SYSTEMATIC ARRANGEMENT)

Keyword• Anybody• Immediately

3 Points• Can See• Can Take Out• Can Return

3 Keys• 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

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Labeling of fixed positions

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Master Card for Drawers

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Place defined and labelling done

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Labeling done on cupboards and maintenance- tool board

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

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•PokaYoke (Error Proofing)

•Master Card for Files

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

3 ‘S’: SEISO (SPIC AND SPAN)

CLEANING TARGETS

Surroundings Storage Areas Equipments & Machines

Make Calendars

3 ‘S’: SEISO (SPIC AND SPAN)

Step 1

•Visual Observation of everything

Step 2

•Practically check everything

Step 3

•Take steps for cleansing

•Measure and calibrate

STEPS CARRIED OUT

Shine Calendar prepared

• Floor mopped• Windows Cleaned

• Kept a separate tea stand (Earlier maintenance

department table was used to keep the tea flask)• Racks etc cleaned

SHINE CALENDAR FOLLOWED

Shine Activity Timing FrequencyResponsible

Person

Workstation

Cleaning

Before starting of

workDaily Operator

Toilets Cleaning 9:00 a.m. & 1:30 p.m. Daily Housekeeping

Sweeping of

Floor9:00 a.m. & 1:30 p.m. Daily Housekeeping

Cleaning of

Office9:00 a.m. Daily Housekeeping

Mopping of Floor Lunch BreakWednesday &

SaturdayHousekeeping

Window Panes Any time of the day Once in a week Housekeeping

Fabric Store/Trim

storeAny time of the day Once in a week Housekeeping

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.

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SOP Cards hung on each machine for ease of operations

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•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

5 ‘S’: SHITSUKE (SELF DISCIPLINE/ SUSTAIN) 0

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EVALUATION AFTER IMPLEMENTATION

week 1.xlsx Week 2.xlsx week 3.xlsx

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•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

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RESULTS AND DISCUSSION

Scores showing execution of 5S on the Knits Floor

Credit wise improvement in all the 5 areas in the execution

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Score Before

ImplementationWeek 1 Week 2 Week 3

28 / 110 39/110 55/110 65/110

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 12

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SCORES SHOWING EXECUTION OF 5S ON THE KNITS FLOOR

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Before Implemen-tationSeries 1Series 2Series 3

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CREDIT WISE IMPROVEMENT IN ALL THE 5 AREAS IN THE EXECUTION OF 5S

1S

2S

3S4S

5S

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WEEK 1WEEK 2WEEK 3

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CONCLUSION

Reducing the stoppage time of the machine increases the overall quality of product.

Standard procedure eases the working and training requirements for operators

The defective items are reduced.

The floor space is utilised properly.

Material handling time is reduced.

Employee involvement is improved.

Easier and safer work environment is partly achieved.

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THANK YOU

BY:

Bhavya Aditya

Surbhi Karn

B.F.Tech (AP), Sem VIINIFT Kangra

2010-2014

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