IMPLEMENTATION OF 5S METHODOLOGY IN DENIM

WASHING DEPARTMENT

A dissertation submitted in partial Fulfilment of the requirement for the award

of Degree in
Bachelor of Fashion Technology (Apparel Production)
Submitted By
Rohan Jetling

Under the Guidance of

Mr. K. Anant Phani
Associate Professor

Department of Fashion Technology

National Institute of Fashion Technology, Hyderabad
May, 2019
 ABSTRACT
5S is a basic foundation of Lean Manufacturing systems. It is a tool for cleaning, sorting,

organizing and providing the necessary groundwork for work piece improvement. By

following the 5S methodology, it shows significant improvements to safety, productivity,

efficiency and housekeeping. The improvements before and after 5S implementation is

shown by pictures in the paper. It also intends to build a stronger work ethic within the

management and workers who would be expected to continue the good practices.

5S is a systematic technique used by organizations come from five Japanese words; Seiri

(Sort), Seiton (Set in order), Seiso (Shine), Seiketsu(standardize) and Shitsuke (sustain). This

system helps to organize a workplace for efficiency and decrease non value added activities

and optimize quality and productivity through monitoring an organized environment. The

results show that 5S is an effective tool for improvement of organizational performance,

regardless of organization type, size, its production or its service. Consequently, 5S technique

would strongly support the objectives of organization to achieve continuous improvement in

performance and productivity

ii
 CERTIFICATE
“This is to certify that this Project Report titled “IMPLEMENTATION
OF 5S IN WASHING DEPARTMENT” is based on my o r i g i n a l
research work, conducted under the guidance of Mr. K. Anant Phani
towards partial fulfilment of the requirement for award of the Bachelor’s
Degree in Fashion Technology (Apparel Production) of National Institute of
Fashion Technology, Hyderabad.
No part of this work has been copied from any other source. Material,
wherever borrowed has been duly acknowledged.”

Rohan Jetling
DFT-VIII

Mr. K. Anant Phani

Associate Professor
Department of Fashion Technology

iii
 ACKNOWLEDGEMENT
The internship opportunity I had with Suryalakshmi cotton mills (Garments

Division), Interning at this industry was a great chance for learning and

professional development. Therefore, I consider myself fortunate to have been

guided in the best possible way. I am also grateful for having a chance to meet

so many wonderful people and professionals who led me through this internship

period.

I am using this opportunity to express my deepest gratitude and special thanks

to my industry mentor Mr. P. Avinash kumar (Washing department- Manager)

who guided me throughout the course of the internship. I would also like to

thank Mr. Venkatesh rao (Process controller- Washing dept.) for his constant

support and supervision and guidance. I extend sincere gratitude to Ms.

Umarani (Human Resource-Head) for providing necessary guidance and

helping in the completion of this project.

I also would like to express my deepest thanks to my faculty mentor Mr. K.

Anant Phani for taking part in the decisions and giving necessary advices and

guidance. I choose this moment to acknowledge their contribution gratefully.

I perceive this opportunity as a milestone in my career development. I will

strive to use the gained skills and knowledge in the best possible way in order to

attain desired career objectives.

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INDUSTRY CERTIFICATE

v
 Table of Contents
1. COMPANY PROFILE: ............................................................................................................................ 1
1.1 Overview: ...................................................................................................................................... 1
1.2 General details: ............................................................................................................................. 1
1.3 Introduction: ................................................................................................................................. 2
1.4 Infrastructure: ............................................................................................................................... 3
1.5 Clients: .......................................................................................................................................... 6
2. DEPARTMENT STUDY: ......................................................................................................................... 7
2.1 Spreading and cutting department: .............................................................................................. 7
2.2 Sewing department:...................................................................................................................... 8
2.3 Washing department: ................................................................................................................... 9
3. PROJECT: ........................................................................................................................................... 17
3.1 Topic of Project: .......................................................................................................................... 18
3.2 Introduction: ............................................................................................................................... 18
3.3 Statement of the problem: ......................................................................................................... 18
3.4 Project Objective:........................................................................................................................ 20
4. REVIEW OF LITERATURE: ................................................................................................................... 21
5. METHODOLOGY: .............................................................................................................................. 24
5.1 Sort: ............................................................................................................................................. 24
5.2 Set in Order: ................................................................................................................................ 27
5.3 Shine:........................................................................................................................................... 30
5.4 Standardize: ................................................................................................................................ 33
5.5 Sustain: ........................................................................................................................................ 34
6. KEYS TO SUCCESFULL IMPLEMENTATION OF 5S: .............................................................................. 36
7. BENEFITS OF 5S: ................................................................................................................................ 38
8. CONCLUSION: .................................................................................................................................... 40
9. REFRENCES: ....................................................................................................................................... 41

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 TABLE OF FIGURES

Figure 1 sorting out the unnecessary and misplaced items ................................................................. 25

Figure 2 Materials organized incorrectly in the warehouse ................................................................. 25
Figure 3 sorting the removable or non-usable materials i.e. Trimmed edges, covers etc. ................. 26
Figure 4 Cutting racks(after) .................................................................... Error! Bookmark not defined.
Figure 5 Cutting racks (before) ................................................................ Error! Bookmark not defined.
Figure 6 Fabric carried from place to place manually.............................. Error! Bookmark not defined.
Figure 7 Fabric carried through carriers .................................................. Error! Bookmark not defined.
Figure 8 Fabric wastage carrier(after)...................................................... Error! Bookmark not defined.
Figure 9 Fabric wastage carrier (before) .................................................. Error! Bookmark not defined.
Figure 11 No proper description and garments arranged improperly before inspection .............. Error!
Bookmark not defined.
Figure 10 Proper description of the checking table ................................. Error! Bookmark not defined.
Figure 12 Un used area in the warehouse(before) .................................. Error! Bookmark not defined.
Figure 13 Un used area in the warehouse(after) ..................................... Error! Bookmark not defined.
Figure 14 Inspection table(after) ............................................................. Error! Bookmark not defined.
Figure 15 Inspection table (Before) ......................................................... Error! Bookmark not defined.
Figure 16 Training program for the staff .............................................................................................. 34
Figure 17 Repeating the activity of spreading awareness periodically to sustain the improvements . 35
Figure 18 Repeating the activity of spreading awareness periodically to sustain the improvements . 35

vii
 1. COMPANY PROFILE:

1.1 Overview:
Partnering leading global brands as an original denim manufacturer, Suryalakshmi Cotton

creates value added denim garments in a variety of styles, colors and finishes. We are a major

denim wear supplier to high street retailers, fashion houses and independent designers across

the globe, for children’s wear, women swear and menswear. Working in close collaboration

with customers’ design teams, suryalakshmi cater to fast fashion requirements with quick

turnaround times.

1.2 General details:

Industry details

Industry Name SURYALAXMI COTTON

MILLS(GARMENTS DIVISION)

Industry location/Postal adress Sy.No 219 Thummalur village, Mahshwaram

Mandal.

Pin code 501359

District Rangareddy I

Industry type Yarn/Textile processing involving in any

effluent/emission generating processes

including bleaching, dyeing, printing and

coloring.

Mandal Thummalur

Scale of industry Large

Status Operational

1
Date of commissioning 20-06-2006

Registration/License No 64758/39170

Gross fixed assessed cost without 1837.0 (in lakhs)

depreciation

Plant and machinery cost without 3092.0 (in lakhs)

depreciation

Status of industry Public limited company

Occupier Name Paritosh kumar Agarwal

Occupier Designation The Managing director

1.3 Introduction:
At Suryalakshmi Cotton, product development is a continuous process across the denim

manufacturing cycle. We draw insights from global fashion experts and trends in the denim

industry to create different garment effects.

-A world-class laundry and dry process facility enables us to create a wide variety of finishes

such as:

 Sand blasting

 Laser cutting

 PP spray

 Crinkling

 Resin finish

 Whiskers

 Chevrons

 Tie and dye

2
  Tinting

 Localized pigment spray

 Grinding

 Damaging

 Ozone finishes

 Spotting etc.

Our garments undergo the highest standard of quality control at every step of production.

With a dedicated merchandizing team combined with highly automated processes, we ensure

consistency in quality and productivity. We recognize and act on our responsibility to respect

worker rights across our garmenting operations and the entire denim supply chain.

Capacity:

5,000 garment pieces per day approx.

1.4 Infrastructure:
At Suryalakshmi Cotton, we understand our business has social and environmental impacts.

With a ‘responsible manufacturing’ approach, we work across our operations – from

material sourcing to yarn manufacturing, fabric manufacturing & garment manufacturing and

from design to delivery – to bring about positive change.

We encourage innovation and promote the integration of more responsible and sustainable

ways of working across the areas of People, Environment and Quality. We have been on

this journey for over 5 decades now and know that real responsibility comes from driving

continuous and measurement-led change in each of these areas

3
At Suryalakshmi cotton mills (Garments division), we have taken the following steps to face

the challenges of a competitive world.

 Improve sustainable supply chain management system.

 Enhance efficiency at every level of production and management.

 Strive to attain highest quality levels as an ongoing process.

 Preserving ethically sensitive trading practices and prudent care of the environment.

 Ensure safety from fire and structural weaknesses.

The company has adopted a comprehensive quality and environment management system

with the objective of making continuous improvement in every aspects of its operation, so

that every employee works together to foster a quality driven culture in the organization.

Prohibition of Discrimination: Equal Opportunity for all

The company will ensure that there is no discrimination, direct or indirect, against any person

on the ground of race, color, nationality, ethnic origin, religion, disability, age, sex, sexual,

orientation, marital status in any aspect of recruitment and selection.

Compensation

Wages paid for regular working hours, overtime hours and overtime differentials shall meet

or exceed legal minimums and /or industry standards. Illegal or unauthorized deductions from

wages shall not be made.

Working Conditions

4
Our company must treat all workers with respect and dignity and provide them with a safe

and healthy environment. The company shall not use corporal punishment or any other form

of physical or psychological coercion.

Workplace health and safety

A clear set of relation and procedures has been established and followed regarding the

occupational health and safety. Our company is committed to implement and where

reasonably practicable, continuously improve effective healthy standards, which should

reflect best industry practice.

Prohibition of child labor

No person irrespective of male or female gender who has not completed 14 years of age are

not allowed to recruit and employ of any nature of job. The rights of young workers must be

protected.

Prohibition of forced labor

Our company does not use any force labor whether in the form of prison labor, indentured

labor, bonded labor or otherwise which is prohibited as per law of the land and/or

international instruments.

5
1.5 Clients:

6
 2. DEPARTMENT STUDY:

The different departments in suryalakshmi cotton mills(Garments division) are:

-Spreading and cutting department

-Sewing department

-Finishing department

-Washing department

-Human resource department

-Industrial engineering department

2.1 Spreading and cutting department:

Spreading and Cutting Department workflow

 Sample Receiving.

 Fabric receiving from store.

 Fabric note as per lot no, shade no, width.

 Sample cutting.

 Sample approval.

 Receiving cut order.

 Marker receiving.

 Fabric spreading / layering.

 Cutting.

 Shading.

 Numbering.

 Bundling.

 Cut quantity report ready.

7
2.2 Sewing department:
-Receive of approval sample, pattern, measurement spec sheet, tech pack, approved trim card,

pp & size set comments & style bulletin.

-Internal pre-production meeting with all concerned department discussed for critical

operation, trims placement, thread shade, quality, machine setting with folders and

attachments, line & delivery plans.

-Batch setting as per style bulletin, with quality checking recorded, type of machine, spy, feed

dog, pressor foot, mockups for critical operations.

-Ensure operator understands operation methods, construction and quality requirement. Time

and method study for line balancing.

8
2.3 Washing department:

Classification of denim washes techniques:

Several types of garment washing for denim fabric are carried out to create varied effects in

denim garments to meet the needs of today’s denim fashion trends. However, each washing

technique has its own advantages and limitations. Denim is either rubbed or worn with stones

and other abrasive materials, called mechanical washing, or treated with bleach and other

kinds of color-altering substances, known as chemical washing.

Mechanical washes include:

 Rinse wash

 Stone wash

 Whiskering

 Microsanding including sandblasting

 Mechanical abrasion

 Laser treatment

 Chemical washing includes:

 Acid wash, ice or snow wash

 Hydrogen peroxide wash or Bleach washing

 Enzyme wash

 Ozone fading

 Spray techniques

 Overdyeing and tinting

The effects desired for denim goods change every year owing to fashion. Various washing

effects have been popularly obtained by laser, sandblasting and enzymatic washing processes.

9
In addition to these processes, hypochlorite bleaching (acid wash) is often preferred,

especially for summer denims.

General finishing sequence of denim:

There are almost countless variations of processing techniques used by designers and textile

chemists to achieve fashionable looks that are distinctive and desirable. The number of

variations is very large and the evolution of chemical and mechanical techniques is

continuing. There often are some secretive and proprietary methods. Regardless of the

specific look and name chosen, the following are the process steps normally used to attain the

desired results.

Flow Chart of Denim Finishing

Desizing
↓
Rinsing
↓
Washing (abrasion)
↓
Rinsing
↓
Softening
↓
Drying
↓
Packing

10
Desizing:

The most popular method of removing starch from denim garments is to use amylase

enzyme. This product can break down the long starch molecular chains (water insoluble)

into smaller molecules (water soluble) which can be more easily washed away. The

removal of starch from the fabric being desized can also usually release some quantities of

indigo into the bath. Therefore, a neutral pH nonionic surfactant is used for suspending

loose dye in the water, to prevent redisposition onto the garments as well as to aid

penetration of the desizing liquor into the interior of the fibers. It is also important to

follow the desizing bath with a hot water rinse. Introduction of cold water onto the denim

garments at this point can re solidify the fats and waxes, and tends to redeposit the

gelatinous components unevenly on surface.

Rinse wash or Regular washing:

Rinse wash is the simplest type of industrial garment wash. The main aim is to remove starch,

dust and dirt from garments. Sometimes reasons for a normal wash include softening and

giving the garment a used look. For color garments, removal of unfixed dyes can be achieved

to improve color fastness. In special cases, intentional shrinkage in garments can be achieved.

Precautions need to be taken against unwanted shrinkage issue and back staining.

Regular washing is the simplest and most commonly used washing method for denim

garments. It is most basic wash for denim garments. Typically named a dark wash, the only

purpose of this wash is to make the garment wearable. The degree of color fading using

regular washing is comparatively slight, but it provides uniformity, depending on whether it

is deeply dyed classic denim or only moderately dyed with poor penetration. Generally

speaking, detergent is used for regular washing for about 15 min at temperatures between 60

11
°C and 90 °C. Softening is applied after the washing process. Regular washing can improve

the softness and comfort properties of denim garments as well as enhance aesthetic property.

Depending on the time and amount of chemicals used, regular washing can be classified into

(1) light washing (washing time about 5 min); (2) normal washing (washing time about 15

min); and (3) heavy washing (washing time about 30 min). However, there is no significant

distinction between light, normal and heavy regular washing as it depends on the actual

washing conditions.

Flow chart of general regular washing process is as follows:

Wetting

Desizing

Regular washing

Softening.

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A sample recipe for a normal wash is:

If the lot size is 100 kg denim pants,

 Material: liquor ratio (M: L ratio)

 Water = 500 L

 Detergent = 1% (based on the weight of the garments)

 Temperature = 40–60°C

 Time = 15–30 min

Back-staining chemical is used if required

Hydrogen peroxide wash or Bleach washing:

Hydrogen peroxide is rarely used as a bleaching agent only when very little loss of colour

is required or if the fabric is coated with sulphur, because it takes longer to achieve the

desired effect. Hydrogen peroxide has a prime role in the bleach wash technique. In an

alkaline medium, hydrogen peroxide breaks up and gives off some perhydroxyl ions, which

destroy the colouring matter and result in a fading effect. Hydrogen peroxide is used in a

scouring, bleaching bath for white textile material or “ready for dyeing” form of garments

made from grey fabrics.

Stone washing:

It is one of the most popular denim wash. It gives a newly manufactured denim garments a

worn-out appearance. It also helps to increase the softness and flexibility of denim

garments otherwise fabric keep stiff and rigid.

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Enzyme washing:

Enzyme wash is a process that gives denim a softer and worn-in look by breaking down the

cellulose molecules naturally found in indigo dyes. Denim washing with enzymes is one of

the most widely accepted enzyme-based. Enzyme washing of denim with various benefits

both economically and environmentally.

Acid washing:

To change the look of denim or jeans different types of washing process are done. Among

various washing process of denim, acid wash is the most popular. This is the oldest of fashion

washes in denim after stone wash.

Microsanding:

A fabric finishing process in which fabrics are sanded (using actual sandpaper) to make the

surface soft without hairiness can be performed before or after dyeing. In this fabric treatment

process, a series of cylindrical rolls in a horizontal arrangement, either wrapped with an

abrasive paper or chemically coated with an abrasive, is used to create a soft suede hand. The

denim is pulled over the face of the sand rollers, creating a raised surface finishing. Some

colour reduction is experienced.

There are three parts to this technique:

1. Sandblasting

2. Machine sanding

3. Hand sanding or hand brushing

Micro sanding is used in various ways: on flat surfaces (tables and ironing boards) or

inflatable dummies (standing, flat or seated). Various templates can be used to create a three-

dimensional (3D) effect.

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Sand blasting:

Sandblasting is a mechanical process of creating fading affect/old looking effect on heavy

garments like denim and jeans. There are two types of sandblasting process: manual

sandblasting and mechanical sandblasting. Both can be deadly. In manual sandblasting,

compressors are used to blow out sand under pressure through a gun in order to bleach and

batter the denim. It is very health hazards for workers. It can give factory workers an

incurable lung disease.

Monkey wash or PP spray:

PP Spray is being done on denim garments to achieve local abraded area to appear whiter

than back ground indigo color shade. PP Spraying(Monkey Wash) means that to spray

potassium permanganate liquid on parts of denim according to design, then there is a

chemical reaction on the denim and fading begin.

Brushing/grinding:

Brushing/grinding (manual or mechanical) is used manually or mechanically for the worn-out

effect, abraded look or used look. Some mechanical processes have been developed that are

based on mechanical abrasion by which the indigo can be removed. Some of these processes

are sueding, raising, immersing, peaching and brushing.

Advantages of these processes are as follows:

Control of the abrasion.

 Different looks on the garment can be achieved.

 All are dry processes.

 Economical, ecological and environmentally friendly.

Brushing is generally being done in a rigid form of garments to get the distressed look.

Locations can be front thigh and seat or it can be overall/global application as is

standard. In the case of hand brushing, emery paper is used to brush the garments in

15
 particular places and designs. Emery paper comes in different numbers, generally

starting from 40 to 600 and higher; the higher the number the finer is the emery paper

(i.e. a lower is a more coarse paper). In the garment industry, 220, 320 and 400 paper

numbers are most popular and widely used

Whisker:

Whiskering refers to thin fading lines formed from creases that are usually found on the front

pocket area of jeans. It is one of the most important design of a used look denim garment.

Now a days it is a common drying process for denim wash.

Ozone fading:

Ozone destroys indigo color on denim in a manner similar to bleaching. Ozone fading of

washed and bleached denim is primarily caused by the oxidative effect of ozone on the indigo

dye, the contaminants and the applied additives. Ozone fading gives the advantage of fading

with a minimum or hardly any loss.

Laser treatment:

Laser fading or marking is a popular dry process for denim now a day. A carbon dioxide

(CO2) laser was used for the colour-fading treatment of denim fabrics. It is sustainable,

environment friendly and emerging industrial approaches for the finishing treatments of the

denim jeans.

16
 3. PROJECT:

IMPLEMENTATION OF 5S METHODOLOGY IN DENIM WASHING

DEPARTMENT

17
3.1 Topic of Project:
Implementation of 5s in Denim washing department

3.2 Introduction:
With the changing techno-economic scenario around the entire world, the market has turned

from seller to buyer. The main object of every organization is to satisfy the stated and implied

needs of the customers. To provide quality product within stipulated time it is necessary to

improve the working conditions. In order to improve the performance of employee,

organization has to create interesting working environment. A pleasant condition can help

improving performance and motivation on the workers. 5S is a system in which to reduce

work and optimize productivity and quality through maintaining and orderly work- place.

The benefit of good workplace include the prevention of defects; prevention of accidents; and

the elimination of time wasted for searching tools, documentation and other ingredients of

manufacture. 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

workplace, elimination of losses connected with failures and breakdowns in machines,

improvement of the quality and safety of work. The implementation of 5S is crucial as it

serves as stepping stones to create a strong housekeeping culture in the organization.

3.3 Statement of the problem:

The key targets of 5S are workplace morale and efficiency. The assertion of 5S is, by

assigning everything a location, time is not wasted by looking for things. Additionally, it is

quickly obvious when something is missing from its designated location. 5S advocates

believe the benefits of this methodology come from deciding what should be kept, where it

should be kept, and how it should be stored. This decision making process should lead to a

18
dialog which can build a clear understanding, between employees, of how work should be

done. It also instills ownership of the process in each employee. The key concept here is to

order items or activities in a manner to promote work flow. For example, tools should be kept

at the point of use, workers should not have to repetitively bend to access materials, flow

paths can be altered to improve efficiency, etc.

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3.4 Project Objective:
 Cleanness and wastage was a major issue in the industry as well as safety workers

would constantly be hurt or constantly be confused of where the things are exactly

located in the warehouse, finishing or cutting areas due to various reasons (improper

machinery, improper description to tables, rusted equipment, no skills in operating the

machine <i.e. spreaders trying to operate with large washing machines and different

types of dyes and chemicals>, no use of safety guards used regularly) leading to

absenteeism or unwilling to work under such situations or unavailability of the

operators

 Suggestion was provided to the industry officials of 5S implementation in Denim

washing department.

 5s in washing department was the demand of one of the Buyer.

 Hence 5S was planned to be implemented.

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 4. REVIEW OF LITERATURE:

5S initially based on the Japanese acronyms of seiri (organization), seiton (neatness), seiso

(cleaning), seiketsu (standardization) and shitsuke (discipline), is used as a platform for

developing an integrated management system by the parallel use of total productive

maintenance.5S usually refers to the five keys to a total quality environment. 5S is a system

to reduce waste and optimize productivity and quality through maintaining an orderly

workplace and using visual cues to achieve more consistent operational results. The practice

of 5S aims to embed the values of organization, neatness, cleaning, standardization and

discipline into the workplace basically in its existing configuration.

The practice of 5S aims to embed the values of organization, neatness, cleaning,

standardization and discipline into the workplace.

To not only survive but thrive in business today, cost must be controlled and waste must be

avoided or eliminated. The 5S steps, when implemented properly, can identify and reduce

many forms of waste in any process or workstation. An organized work area reduces

excessive motion and wasted time looking for the right tool. The visual aspect of the 5S

Methodology is also very effective. When everything has a place, it is easier to spot

something missing or misplaced. A clean work area helps draw attention to possible problems

or safety hazards. A clean floor helps spot any leaks or spills could indicate machine

maintenance and prevent slips and falls. Furthermore, encouraging people to watch for and

address problems can result in a positive change to an organizations culture. Therefore, the

5S Principles implemented as part of a larger Lean initiative or as a standalone tool can

reduce waste, improve quality, promote safety and drive continuous improvement.

21
5s Defined as:
Systematic Practicing of Good habits like organizing cleaning, sustaining, is what is

emphasized in 5S. 5S is a more “DO IT YOURSELF” approach changing the mindset is very

important.5S is one of the most widely adopted techniques from the lean manufacturing

toolbox.5S is considered a "foundational" lean concept.

The primary objective of 5S is to create a clean, orderly environment- an environment where

there is a place for everything and everything is in its place.

The 5S's are:

• Seiri: Separating. Refers to the practice of going through all the tools, materials, etc., in the

work area and keeping only essential items. Everything else is stored or discarded. This leads

to fewer hazards and less clutter to interfere with productive work.

• Seiton: Sorting. Focuses on the need for an orderly workplace. "Orderly" in this sense

means arranging the tools and equipment in an order that promotes work flow. Tools and

equipment should be kept where they will be used, and the process should be ordered in a

manner that eliminates extra motion.

• Seisō: Shine. Indicates the need to keep the workplace clean as well as neat. Cleaning in

Japanese companies is a daily activity. At the end of each shift, the work area is cleaned up

and everything is restored to its place. The key point is that maintaining cleanliness should be

part of the daily work - not an occasional activity initiated when things get too messy.

• Seiketsu: Standardizing. This refers to standardized work practices. It refers to more than

standardized cleanliness (otherwise this would mean essentially the same as "systemized

cleanliness"). This means operating in a consistent and standardized fashion. Everyone knows

exactly what his or her responsibilities are.

22
• Shitsuke: Sustaining. Refers to maintaining standards. Once the previous 4S's have been

established they become the new way to operate. Maintain the focus on this new way of

operating, and do not allow a gradual decline back to the old ways of operating.

Month Target: 125000

Total dispatch quantity: 129600

Difference: 4600

Benefits-Waiting time was reduced

-Non value added activities were removed

23
 5.METHODOLOGY:

The 5S Method is a standardized process that when properly implemented creates and

maintains an organized, safe, clean and efficient workplace. Improved visual controls are

implemented as part of 5S to make any process non-conformance’s obvious and easily

detectable. 5S is often one element of a larger Lean initiative and promotes continuous

improvement.

5.1 Sort:

Following are the steps of performing Seiri:

*If there are any unnecessary things which is causing mixing of things should be clear out.

*Any unnecessary part of the item placed other side should be brought back to its original

position.

*Tools of material which lie on production floor should be in the tool floor.

*Check weather all necessary things sorted to its own place.

*All tools are classified properly with the rule.

*After all these step, we will use Red Label or Red Tag technique, this technique is applied to

all the unnecessary items for its recognition

24
Figure 1 sorting out the unnecessary and misplaced items

Figure 2 Materials organized incorrectly in the warehouse

25
 Figure 3 sorting the removable or non-usable materials i.e. Trimmed edges, plastic covers, cartoons etc.

Benefits of Seiri:

*Improve the processing in the work place.

*Reduction in the cost.

*Solves the problem of Stock of item.

*Problem of losing tools eliminated.

*Better Work area

26
5.2 Set in Order:

Following are the rules of performing Seiton:

*Position of every place should be decided earlier where items supposed to be placed.

*All tools should be segregated on the basis of regular uses.

*Put all the important items in an accessible position where it can be brought easily.

*Small tools should be placed in a specific place or recognized place.

*Safety equipments should be placed in the right position for emergency requirement.

Before: After:

Figure 5 Cutting racks (before) Figure 4 Cutting racks(after)

27
 Before: After:

Figure 6 Fabric carried from place to place manually Figure 7 Fabric carried through carriers

Before: After:

Figure 9 Fabric wastage carrier (before) Figure 8 Fabric wastage carrier(after)

28
Benefits of Seiton:

*Increases the efficiency of the production.

*Effectiveness increases.

*Time required for seeking the items are reduced.

*Improves the safety.

29
5.3 Shine:

Following are the rules of performing Seiso:

*Check roughly everything, and clear all major source of unnecessary things.

*Clean all the machines present in the work shop on daily basis.

*Check all the tools, equipments on weekly basis, and provide necessary cleaning.

*Clean the shop floor & work floor.

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PP SPRAY CHECKING TABLE:

Before: After:

Figure 10 No proper description and garments arranged Figure 11 Proper description of the checking table
improperly before inspection

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Before: After:

Figure 12 Un used area in the warehouse(before) Figure 13 Un used area in the warehouse(after)

Benefits of Seiso:

*Cleans the workplace.

*Increases the efficiency of machines.

*Maintains the cleanness in the industry.

*Finds the errors in the workplace.

*Eliminates accidents due to cleanness.

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5.4 Standardize:

Following are the rules of performing Seiketsu:

*Give strict instructions about cleanness to the whole staff.

*Maintain habit to check the progress in the cleanness.

*Make an audit sheet to ensure cleanness

Final inspection table:

Before: After:

Figure 15 Inspection table (Before) Figure 14 Inspection table(after)

Benefits of Seiketsu:

*Increases the safety of industry.

*Reduction in the pollution created by industry.

*Maintains the good habit among the staffs about cleanness

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5.5 Sustain:

Following are the rules of Shitsuke:

*Manager of the industry should take the responsibility to held a program for 5S rule.

*Staffs should also be eager to learn the technique

Figure 16 Training program for the staff

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.

Figure 18 Repeating the activity of spreading Figure 17 Repeating the activity of spreading
awareness periodically to sustain the improvements awareness periodically to sustain the improvements

Benefits of Shitsuke:

*Increases the awareness among the staffs.

*Reduces mistake resulting by staffs.

*Improves relations between the staffs.

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 6. KEYS TO SUCCESFULL IMPLEMENTATION OF 5S:

• Get everyone involved – 5S is not be the responsibility of a concerned few. It is a concern

of everyone to act. All levels of management should take part in decision making required to

ensure 5S implementation. Incorporate 5S activities as part of company’s small group

activities. • Get company authorization – 5S activities should not be performed in a secret or

disguised such as overtime work. Get management approval for all 5S activities. Make signs

and posters as means to promote 5S to everyone. Conduct a general monthly meeting where

company and managers can address 5S issues and themes. • Final responsibility rests with the

president – The 5S’s will not be taken seriously until the managers and even the company

president takes personal responsibility and interest on its implementation. Nothing could be

worse for the success of 5S implementation than to have managers who “pass the 5S

implementation buck” to their subordinates. Company managers must take a strong

leadership role in 5S promotional meetings and other 5S events. • Make yourselves

understood and aware of - Don’t leave people wondering “Why are we sticking red tags on

things?” or ”Is all this 5S stuff really necessary before we can make any improvements?”.

Hold 5S promotional meetings to explain 5S and to entertain all questions from all

participants. Present actual examples from successful 5S implementation, or take participants

on tour on successful 5S workplaces. • Do it all the way – When establishing proper

arrangement, make sure to carry out all the tag campaigns and use correct red tagging formats

and procedures. When establishing orderliness, use signboards. Make sure that signboards

have proper format, descriptions and locations. Prepare your company’s own 5S manual,

complete with all the necessary details. • The president should inspect the shop floor

personally - The president should personally inspect offices and point out their various

positive and negative conditions.

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• Don’t stop halfway in establishing 5S - Don’t do things halfway. Once the 5s promotional

organization and methods have been established, get started and stick with it. When

developing red tagging and signboards throughout the company, make sure gets everyone

involved. Ones you have laid the foundation by establishing proper arrangement and

orderliness, start developing discipline habit to keep the foundation strong. • 5S is a half way

towards other improvements – don’t stop with 5S; follow through with zero defects, cost

reduction and other productivity and quality improvements. Once the office has been cleaned

up, start putting casters on drawer cases to make them easily movable. Eliminate defects as

close to their source as possible and implement flow process.

By implementing 5S eventually productivity, efficiency and working spirit will be promoted.

It is not only useful to manage workplace physically but also useful to develop employee’s

attitude and discipline

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 7. BENEFITS OF 5S:

• Increased Productivity:

Every organization works towards achieving increased productivity, after all,

productivity increases the overall return on investment. According to global research

done by various consultancy firms in the US, it has been found that effective

implementation of 5S lean manufacturing resources provides this improvement.

The compete removal of unnecessary items along with efficient workplace

maximization is sufficient to help develop improved productivity with minimal

wastage of time. Less time spent searching through unnecessary items means more

time spent working.

• -Improved Safety

Improved safety is yet another benefit of 5S implementation. A clean workplace

environment, especially in a manufacturing unit can result in significant reduction in

the number of injuries sustained by workers. Most often, unattended chemical spills

increases the chances of slips and falls.

Contrary to this, following methodical procedures of cleaning, limits the possibility of

all such unfortunate mishaps. Also, the reduction in unnecessary travel through the

workspace environment further minimizes the risk of sustaining injuries by limiting

exposure to hazardous substances elsewhere in the facility. This in return functions to

increase the moral of employees, as reduced incidents of injuries convey employer’s

concern for worker safety.

• - Reduction in Waste

Implementing 5S will also yield a fair reduction in lost and damaged items in the

workplace.

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• A clear and organized workplace with proper labelling provides workers the

flexibility to replace damaged items in the designated places, thereby minimizing the

total number of misplaced and lost tools and equipment. Further, the appropriate

management of equipment also minimizes damages that are generally caused to

various parts of the products during the production process.

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8. CONCLUSION:

The suggestive solutions provided through this Japanese 5S System application in the

sample section of apparel industry reflected as a great effective tool for smooth

production and dispatch with better quality sample. Hence, also an excellent relation build

up with the buyer side and thus a better scope to have more production order for the

apparel industry which is highly expected from manufacturer’s side. This system is

already globally recognized and gained huge fame by improving Productivity, Quality

and Safety at work.

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9. REFRENCES:

https://en.wikipedia.org/wiki/5S_(methodology)

https://www.simplilearn.com/implementing-5s-methodology-to-achieve-workplace-

efficiency

http://leansixsigmadefinition.com/glossary/5s/

https://quality-one.com/5s/

https://www.creativesafetysupply.com/content/education-research

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