PRODUCTIVITY

IMPROVEMENT BY
IMPLEMENTING 5S SYSTEM
Submitted by
C.S.LOGESHWAR 17M059
R.SHRI HARI PRASAD 17M069
R.MADHANRAJ 18MH12
N.SRI SAKTHI DHASAN 18MH14
 INTRODUCTION

5S METHODOLOGY HAS EXPANDED FROM MANUFACTURING AND IS NOW BEING

APPLIED TO A WIDE VARIETY OF INDUSTRIES INCLUDING HEALTH CARE, EDUCATION,
AND GOVERNMENT. VISUAL MANAGEMENT AND 5S CAN BE PARTICULARLY
BENEFICIAL IN HEALTH CARE BECAUSE A FRANTIC SEARCH FOR SUPPLIES TO TREAT AN
IN-TROUBLE PATIENT (A CHRONIC PROBLEM IN HEALTH CARE) CAN HAVE DIRE
CONSEQUENCES. ALTHOUGH THE ORIGINS OF THE 5S METHODOLOGY ARE IN
MANUFACTURING, IT CAN ALSO BE APPLIED TO KNOWLEDGE ECONOMY WORK, WITH
INFORMATION, SOFTWARE, OR MEDIA IN THE PLACE OF PHYSICAL PRODUCT. THE
OUTPUT OF ENGINEERING AND DESIGN IN A LEAN ENTERPRISE IS INFORMATION, THE
THEORY BEHIND USING 5S HERE IS "DIRTY, CLUTTERED, OR DAMAGED SURFACES
ATTRACT THE EYE, WHICH SPENDS A FRACTION OF A SECOND TRYING TO PULL USEFUL
INFORMATION FROM THEM EVERY TIME WE GLANCE PAST. OLD EQUIPMENT HIDES THE
NEW EQUIPMENT FROM THE EYE AND FORCES PEOPLE TO ASK WHICH TO USE
5S EXPLANATION.
1. Sort ( seiri ): Seiri is sorting through all items in a location and removing all
unnecessary items from the location.
Goals:
• Reduce time loss looking for an item by reducing the number of items.
• Reduce the chance of distraction by unnecessary items.
• Simplify inspection.
• Increase the amount of available useful space.
1S Sort Implementation: we separated all the components in the racks
accordingly and removed the unnecessary items and we ensured the
components are shorted and placed in convenience to the workers . we
eliminated clutter and clear uped space by removing things that don’t
belong in the rack
Set in order (seiton): Seiton is putting all necessary items in the
optimal place for fulfilling their function in the workplace.
Goal: • Make the work flow smooth and easy.
Implementation: the components were Arranged in the work
stations in such a way that all components is in close proximity in an
easy to reach spot and in a logical order adapted to the work
performed. 18 Place components according to their uses, with the
frequently used components being nearest to the workplace.
• Arranged all necessary items so that they can be easily selected
for use. Make it easy to find and pick up necessary items. Assign
fixed locations for items. Use clear labels, marks or hints so that items
are easy to return to the correct location and so that it is easy to
spot missing items.
Shine (seiso): Seiso is sweeping or cleaning and inspecting the
workplace, tools and machinery on a regular basis.
Goals:
• Improves the production process efficiency and safety, reduces
waste, prevents errors and defects.
• Keep the workplace safe and easy to work in.
• Keep the workplace clean and pleasing to work in.
Implementation : All the components were cleaned and the racks
were cleaned completely and then the components were setted in
order
Standardize (seiketsu) : Seiketsu is to standardize the processes used
to sort, order and clean the workplace.
Goal: Establish procedures and schedules to ensure the repetition
of the first three ‘S’ practices.
Implementation: • Develop a work structure that will support the
new practices and make it part of the daily routine.
• Ensure everyone knows their responsibilities of performing the
sorting, organizing and cleaning.
• Use photos and visual controls to help keep everything as it should
be.
• Review the status of 5S implementation regularly using audit
checklists
STANDARDIZE
Before and after picture of a rack
where bin method is implemented
to organise the essential small sized
components in a orderly manner
so that workers find them easily
without delay and confusion
Sustain (shitsuke):
Shitsuke or sustain the developed processes by self-discipline of the
workers. Also translates as "do without being told".
Goal: Ensure that the 5S approach is followed.
Implementation:
Organize racks were labled and mapped and a sheet was
provided containing the location of components and was
provided to the person in charge and another informative sheet
was sticked infront of the rack to make sure they are maintained in
the same location
Propel was started in the year 2009 to cater to
the Crushing and Screening industry and in
less than a decade has rapidly risen to COMPANY
become one of the industry leaders with over INTRODUCTION :
1200 clients across India and abroad. The
propel industries manufactures rock crushing
machines at the cheaper rate compared to
other companies with were much low
maintenance cost .
List of their few main products:
• TRACK VSI. TS 1861-4D.
• SEMI MOBILE PLANTS. PROFAST JAW. PROFAST
CONE. PROFAST VSI.
• GYRATORY CONE CRUSHER. Horizontal Shaft
Impactor. Roll Crusher.
• MVS INCLINED SCREENS.
• THICKENER.
PURPOSE OF THE PROJECT
5S Is a leading system which helps the company to increase the
productivity rate by implementing its principles inside the worksite to help
the works and make them feel comfortable in working and eliminating the
wastes of time in searching things. The purpose of the project was to
eliminate the wastage of time and to calculate the estimated time for that
particular process and standardize the process time and also to have a
comfortable and organized working space for the workers
ADVANTAGES OF OUR PROJECT:
INCREASED PRODUCTIVITY.
IMPROVED SAFETY.
REDUCTION IN WASTE.
WORKER COMMITMENT.
ORGANIZED WORKSPACE.
EASY ESTIMATION OF PROCESS DURATION.
WORK MADE EASY FOR WORKERS
SEARCH TIME REDUCED
ELIMINATING MACHINERY WASTE
INCREASED UPTIME
HIGHER EFFICIENCY
METHODOLOGY
CONCLUSION :
The racks where the components are kept were not arranged properly and
it was hard for the labours to find the location of the component they
need. After arranging all the components in the particular track with
proper planning and marking by dividing the rack with floor marking tapes
on the rack considering the dimensions of the component with a list and
the components were neatly and visibly labelled on the rack with a proper
information the workers were able to find the component In time with-out
any such efforts it helped them to reach the component in time without
any delay.
Thus the 5s method implemented in the company for the betterment of the
workers to reach the components in time and have an easy and safe
working environment which also helps in increasing the production rate of
the company. All the companies are directly or indirectly depended on
the workers they are the backbone for every company the production rate
is always depended on the workers so the 5s method implementation in
the propel industry made the workers job little easy and organized.
Propel private limited company manufactures have succeed a lot
in their short spam of time the total turn over of the company is
enormous and grows every year. We were allowed to implement in
a particular section where they assemble screen one of the
companies product . the racks were filled with lots of components
in an improper manner which made the labours to take more time
to identify the exact location of the component we rearranged all
the components in the rack in the particular track with proper
labelling and markings and with a location information sheet which
made the work little easier for the labours to get the required
components in time which make them to concentrate on the given
job rather searching the component for a long time we have
reduced the searching time of components and helped in
increasing the production rate