6S Cost Analysi-Final Ok

6S Cost Analysis
No.of.department cost savings Cost savings Per

Sl.No Activities benefits Savings UOM
s per month(₹) year (₹)
inch square
1 5 Sorting Space Saving 136 5440 5440
feet
waste or unnecessary materials are
2 15 Sorting 138 Quantity 34471 34471
reused
3 20 Set in order Tools searching Time reduced 308.27 Hr/Year 1337 16054
Tools handling and Work handling
4 3 Set in order 83.2 Hr/year 361 4333
time reduced
5 1 Set in order Rework time reduced 8.66 Hr/year 38 452
inch square
6 1 standardisation space saving 2 80 80
feet
Tools consumption, rework time 5+ 500 tool

7 5 standardisation Hr/tool/day 5979 5979
and unnecessary stocks reduced cost
Total 47706 66809

6S Cost
6S Audit 6S Audited Activities on During 6S Audit
6S Audit Report Department
SL.No Date Number name Activities Problem discription
last 10 years old files and

1 4/22/2021 2021-0260 Voucher and Sorting papers are Stored in the work
Logistics
area which are not needed
unnecessary materials like box,

water battles are stored in the
2 4/10/2021 2021-0258 High-end cell Sorting
department (one full wooden
racks are unnecessary materials)
old job card , unnecessary

papers and non used 3 steel
3 3/20/2021 2021-0247 Platinum sorting boxs are kept in the
department
non used boxes and Files, cans,

4 3/3/2021 2021-0240 Fire Assy sorting steel boxs are kept in the
department
un necessary materials like one

5 2/19/2021 2021-0237 Imprez sorting phone and other un specified
materials are stored in the
department
Total
6S Cost Ana
6S Audit 6S Audit 6S Audited Activities on During 6S Audit
SL.No Report Department
Date Number name Activities Problem discription
around 80 tag files are stored in

the department for future use
1 4/22/2021 2021-0260 Voucher and Sorting but it is currently not in use and
Logistics their monthly inventry ratios are
very high according to their
indent
6S Cost Analysis Report - Sorting
Activities on After 6S Audit
Solutions benefits
Length in feet
unnecessary files and old papers Space Saving in square
are removed from the work area feet 6
unnecessary material quality Space Saving in square

should be checked and it should 8
be handovered to stores. feet
materials can used to some other Space Saving in square

works feet 8
un necessary materials should be Space Saving in square

8
removed from the work area feet
unnecessary materials stored the Space Saving in square 8

department to be removed feet
38
6S Cost Analysis Report -standardisation

Solutions benefits
Length in feet
currently available stocks to be
handover to stores and the
Inventory stock register to be
maintained and monitored in the Space Saving in square
feet 2
department for avoiding
unnecessary investment on
inventory
tivities on After 6S Audit
fits One Square feet Rent cost per
Square feet
Width in feet (Rent cost ₹) square feet
4 24 40 960
2 16 40 640
4 32 40 1280
4 32 40 1280
4 32 40 1280
18 136 5440
tivities on After 6S Audit

fits One Square feet Rent cost per
Square feet (Rent cost ₹) square feet
Width in feet
1 2 40 80
6S Audit
S.No Date Report Department Activities on During 6S
Number Name
Voucher and
1 4/22/2021 2021-0260 Logistics Sorting
Voucher and
2 4/22/2021 2021-0260 Logistics Sorting
3 4/22/2021 2021-0260 Voucher and Sorting

Logistics
4 4/10/2021 2021-0258 High-end cell sorting
5 3/4/2021 2021-0256 CNC Bangle sorting
7 4/2/2021 2021-0255 Indiania sorting
8 4/1/2021 2021-0253 Canteen sorting
9 3/30/2021 2021-0252 Line cell 3 sorting

12 3/22/2021 2021-0248 Turkey Cell sorting
15 3/6/2021 2021-0241 stamping sorting
casting and M-
19 3/15/2021 2021-0245 Sorting
lab
casting and M-
20 3/15/2021 2021-0245 lab Sorting
Seperation and
21 3/17/2021 2021-0246 spare parts sorting
22 3/17/2021 2021-0246 Seperation and sorting

spare parts
Seperation and
23 3/17/2021 2021-0246 spare parts sorting
Seperation and
24 3/17/2021 2021-0246 sorting
spare parts
25 3/13/2021 2021-0244 wax sorting
26 3/10/2021 2021-0243 customer cell sorting
30 3/10/2021 2021-0243 Diamond cell Sorting
33 3/1/2021 2021-0239 Handmade sorting

37 2/22/2021 2021-0238 fusion sorting
38 2/22/2021 2021-0238 fusion sorting
39 2/22/2021 2021-0238 fusion sorting
Total
Materials Type Quantity Cost

Furniture 28 19496
Equipment and 96 14725
Materials
Stationery 14 250
Total 138 34471
6S Cost Analysis Report
Activities on During 6S Audit Materials Type
last 10 years old files and papers

waste Reduction and Cost
are Stored in the work area which saving Stationery
are not needed

waste Reduction and Cost
are Stored in the work area which saving Stationery
are not needed

are Stored in the work area which waste Reduction and Cost Stationery
saving
are not needed
since 6 days, Rubber mats are

Resources reused Equipment and Materials
stored in red tag area
around 6 to 10 materials are found

materials waste reduced Equipment and Materials
non usable in department
around 6 to 10 materials are found

non usable in department materials waste reduced Stationery
2 chairs are not used and it is kept

materials waste reduced Furniture
in red tag area
non used materials are kept in

canteen (empty boxes)
2 chairs and one wooden rack, 2

motors are stored in red tag area materials waste reduced Furniture
2 chairs and one wooden rack, 2

motors are stored in red tag area materials waste reduced Furniture
2 chairs and one wooden rack, 2 materials waste reduced Equipment and Materials
motors are stored in red tag area
non used items like 5 item tray and
2 wooden draw and 10 acrylic materials waste reduced Furniture
sheets are kept in work area

2 wooden draw and 10 acrylic materials waste reduced Equipment and Materials

2 wooden draw and 10 acrylic materials waste reduced Equipment and Materials
non used item of wooden racks

and chairs, stone box and steel materials waste reduced Furniture
boxes are kept in the department

and chairs, stone box and steel materials waste reduced Equipment and Materials

and chairs, stone box and steel materials waste reduced Equipment and Materials

and chairs, stone box and steel materials waste reduced Furniture
buffing motor and chairs are kept

in red tag area
buffing motor and chairs are kept

in red tag area materials waste reduced Furniture
non used items like 5 rubber mats,

chair, steel box, item trays are materials waste reduced Equipment and Materials
kept in the department

chair, steel box, item trays are materials waste reduced Furniture

non used 6 chairs are kept in the

AHU room materials waste reduced Furniture
non used items like 6 item trays , 3

lamps, one chair,3 steel box are materials waste reduced Equipment and Materials
improperly stored in department

lamps, one chair,3 steel box are materials waste reduced Furniture


non used items like 3 chairs, 6

lamps, 4 steel boxs are kept in the materials waste reduced Furniture
department

lamps, 4 steel boxs are kept in the materials waste reduced Equipment and Materials
department
lamps, 4 steel boxs are kept in the materials waste reduced Equipment and Materials
department
non used items like 20 rubber

mats, one wooden rack, 5 item materials waste reduced
and inventory cost Equipment and Materials
trays, one magnetic board are controlled
stored in the red tag area

materials waste reduced
mats, one wooden rack, 5 item and inventory cost Furniture
non used items like 20 rubber materials waste reduced
mats, one wooden rack, 5 item
trays, one magnetic board are and inventory cost Equipment and Materials
controlled

mats, one wooden rack, 5 item materials waste reduced
and inventory cost Equipment and Materials
unnecessary materials like plastic

box, key board, wooden draw are materials waste reduced Furniture

box, key board, wooden draw are materials waste reduced Equipment and Materials

box, key board, wooden draw are materials waste reduced Equipment and Materials
Total
s Report
Materials Materials
Materials Name Quantity Purchase Purchase used life
Cost / per Cost / total
item in₹ item in₹
Tag files 5 30 150 1
shredded paper 1kg 10 10
Rubber mats 6 100 600 2
Item moving tray 6 300 1800 1
Plastic chairs with steel leg 2 1000 2000 1
Plastic chairs with steel leg 2 1000 2000 1
wooden rack with

cupboards 1 1000 1000 2
buffing motors 2 2000 4000 1

Cutting table cupboard draw 5 500 2500 2
Acrylic sheets aluminium 10 100 1000 1
wooden rack 3 step

cupboards 1 1500 1500 2
Stone box 1 100 100 1
Steel box 1 100 100 1
workers plastic chair with

2 1000 2000 1
steel leg
buffing motor 1 3000 3000 2

steel leg 1 1000 1000 1
Floor rubber mats 5 100 500 1
workers plastic chair with 2 1000 2000 1

steel leg

Steel box 2 100 200 1
worker yellow wire Steel

chairs 6 1999 11994 1

steel leg 1 1000 1000 1
Steel box 3 100 300 1
Lamp for correction work 3 100 300 1

steel leg 3 1000 3000 1
Steel box 4 100 400 2
Lamp for correction work 6 100 600 1
20 rubber mats 20 100 2000 1
wooden rack 1 1000 1000 1

magnetic notice board 1 1000 1000 1
wooden draw 1 500 500 1
key board 1 150 150 1
138
Old
product product Cost benefit
life cost
3 50 100
10 10
3 50 100
4 300 300
2 900 900
3 80 40
3 666.6666667 1333.33333333333
3 400 800
4 500 1500
4 500 500
5 800 3200
3 1666.666667 833.333333333333
3 500 1000
3 333.3333333 666.666666666667
3 1000 500
2 50 50
3 33.33333333 66.6666666666667
3 666.6666667 1333.33333333333
4 1500 1500
2 500 500
3 166.6666667 333.333333333333
3 666.6666667 1333.33333333333
4 300 300
3 66.66666667 133.333333333333
3 3998 7996
3 600 1200
3 333.3333333 666.666666666667
4 75 225
3 100 200
3 1000 2000
4 200 200
3 200 400
4 500 1500
3 333.3333333 666.666666666667
4 750 750
2 500 500
3 166.6666667 333.333333333333
3 200 400
3 50 100
34471
Activities on During 6S Audit
6S Audit 6S Audited
SL.No 6S Audit Report Department
Date Number name Activities
1 4/22/2021 2021-0260 Voucher and Set in order

Logistics
2 4/10/2021 2021-0258 High-end cell Set in order
3 4/5/2021 2021-0257 MMD Set in order
4 4/2/2021 2021-0255 Indiania set in order
5 4/1/2021 2021-0253 canteen set in order

6 3/30/2021 2021-0252 Line cell 3 set in order
7 3/22/2021 2021-0248 Turkey Cell set in order
8 3/6/2021 2021-0241 stamping set in order
9 3/20/2021 2021-0247 Platinum set in order
casting and M-
10 3/15/2021 2021-0245 set in order
lab
Seperation
11 3/17/2021 2021-0246 and spare set in order
parts
12 3/13/2021 2021-0244 wax set in order
13 3/10/2021 2021-0243customer cell set in order
14 3/10/2021 2021-0243 Diamond cell set in order
15 3/3/2021 2021-0240 Fire Assy set in order
16 3/1/2021 2021-0239 Handmade set in order
17 2/22/2021 2021-0238 fusion set in order

19 2/19/2021 2021-0237 Imprez set in order
20 2/17/2021 2021-0236 QA set in order
21 2/17/2021 2021-0236 QA set in order
22 2/16/2021 2021-0235 Security set in order
Total
6S Audit 6S Audit 6S Audited

Date Number name
6S Audit 6S Audited
SL.No 6S Audit Report Department
Date Activities
Number name
1 4/5/2021 2021-0257 MMD Set in order
2 4/3/2021 2021-0256 CNC Bangle set in order
Total

6S Audit 6S Audited
6S Audit
Date
Number name
6S Audit 6S Audited
6S Audit
Date Activities
Number name
1 4/5/2021 2021-0257 MMD Set in order
6S Audit 6S Audited
6S Audit
SL.No Date Report Department
Number name Activities
10 4/10/2021 2021-0258 High-end cell Standardisation
15 4/5/2021 2021-0257 MMD standardisation

19 3/4/2021 2021-0256 CNC Bangle standardisation
22 4/2/2021 2021-0255 Indiania standardisation
58 3/1/2021 2021-0239 Handmade standardisation
Total
6S Cost Analysis Report - Set i
tivities on During 6S Audit A
Problem Description Solutions benefits
Files are not stored in All files are labelled and it

proper location and there is properly stored in
is no allocated location with Searching time
reduced
numbering , Indexing easily accessible to
system in files everyone.
materials are improperly materials should be placed

searching Time
stored in the racks with out in racks with proper reduced
any labels location and labels
after usage the Tools

Used tools are not stored should be placed in searching Time
properly in the allocated allocated location and the
Location tools check list should be reduced
followed
Tools are not properly Tools are properly stored

stored and labelled in and labelled in allocated Tool searching Time
reduced
allocated location location
materials are properly

materials are not properly Labelled and stored in its searching Time
stored and neither labelled
allocated location with its reduced
in its allocated location.
stock register
consumables are stagnant materials can properly
improperly in racks which stored and labelled in searching Time
are non usable and stock allocated location with reduced
register not maintained register
materials can properly

materials are nor properly
stored and neither labelled stored and labelled in searching Time
allocated location with reduced
in its allocated location.
register

Tools and materials are not Labelled and stored in its searching Time
properly Labelled and
stored in allocated location
stock register
tools, dies, materials are materials can properly

nor properly stored and stored and labelled in searching Time
neither labelled in its allocated location with reduced
allocated location. register
tools, dies, materials are materials can properly

nor properly stored and stored and labelled in searching Time
neither labelled in its allocated location with reduced
allocated location. register
all tools, items, spares,

materials are not properly materials are properly
Labelled and stored in its searching Time
Labelled and stored in the
allocated location with allocated location with its reduced
stock register
register
dies, tools, materials are materials can properly
not properly Labelled and stored and labelled in searching Time
stored in the allocated allocated location with reduced
location with register register
tools and materials are not materials are properly

properly Labelled and Labelled and stored in its searching Time
stored in the allocated allocated location with its reduced
location stock register

properly Labelled and Labelled and stored in its searching Time
stored in the allocated allocated location with its reduced

properly Labelled and Labelled and stored in its searching Time is
stored in its allocated allocated location with its reduced

materials are not properly
Labelled and stored in the Labelled and stored in its searching Time
allocated location
stock register
files are not properly files are properly Labelled

searching Time
Labelled and stored in the and stored in the allocated
allocated location location reduced
tools and materials are not tools and materials are
properly Labelled and properly Labelled and searching Time
stored in the allocated stored in the allocated reduced
location location
dies are stored in very

height location and it's dies are properly Labelled searching Time
improperly labelled and and stored in its allocated
reduced
stored in the allocated location
location
files are not properly files are properly Labelled

searching Time
Labelled and stored in its and stored in the allocated
reduced
allocated location location
numbering system not

properly implemented for numbering system to be searching Time
implemented reduced
lights
materials are not properly materials are properly searching Time

Labelled and stored in its Labelled and stored in its
reduced
allocated location allocated location
numbering system not numbering system to be searching Time

properly implemented for
implemented reduced
lights
Total
6S Cost Analysis Report- Set in order ( Tool

pathways access to tool

path ways access to tool Tool handling time is
handling was blocked handling should be free high
from blockages
Tools are not properly

Labelled and stored in its seperate location allocated Tool handling time
allocated location. for tools storage handlings
(opening draw and taking with marking and labelling reduced
dies)
seal contents to be printed

Doing sealing works on in job cards and use. work handling time
contents in papers should
papers is repeated task reduced and sealing
be reviewed because lot of
and paper consumption is paper wasted due to work process on
high papers eliminated
content not properly filled
in papers
Total
6S Cost Analysis Report- Set in

tivities on During 6S Audit
Input and output location Rework occurs due to parts Rework occurs due
not allocated for process mixup to parts mixup
6S Cost Analysis Report - Standardisati

Inventory and
Tool consumptions are resources waste
high,and Tool life is not Tool life need to be fixed
monitored in the and monitored reduced, tool setting
department time + Rework Time
reduced
Tool life need to be spending cost for

Tools check list and monitored and
tool reduced + tool
maintenance check lists consumables and setting time and
are not updated maintenance record should
rework time reduced
be updated
stocks are not defined for stocks are need to be Rework Time
production defined and monitored reduced
preventive maintenance Preventive maintenance Maintenance cost

not done for soldering should be properly and service time
machine maintained reduced
cutting-tools life not worn cutting tools are

spending cost for
monitored and worn tools reused with the help of tool reduced
are not re-used grinding work
Total
ysis Report - Set in order - setting time reduced
Activities on After 6S Audit (Average salary taken for cost calculation ( =1250
Before 6S
Before 6S Audit After 6S Audit Audit
(searching Time in (searching Time in Savings in sec /day (searching
Sec /day) Sec /day) Time in
hrs/day)
360 240 120 0.1
360 180 180 0.1
240 80 160 0.066666667
240 120 120 0.066666667
90 45 45 0.025
240 120 120 0.066666667
360 180 180 0.1
360 180 180 0.1
360 180 180 0.1
360 180 180 0.1
360 180 180 0.1

360 180 180 0.1
360 180 180 0.1
360 180 180 0.1
360 180 180 0.1
360 180 180 0.1
360 180 180 0.1

360 180 180 0.1
720 180 540 0.2
60 20 40 0.016666667
12 8 4 0.003333333
120 60 60 0.033333333
12 4 8 0.003333333
6774 3217 3557 1.881666667
et in order ( Tool handling and work handling time reduced)

Before 6S
Before 6S Audit After 6S Audit (Tool Audit (Tool
(Tool handling Time handling Time in Savings in sec/day handling
in sec/day) sec/day) Time in
hrs/day)
120 60 60 0.033333333
600 300 300 0.166666667
600 0 600 0.166666667
1320 360 960 0.366666667
ysis Report- Set in order ( Rework time reduced)

Before 6S
After 6S Audit
Before 6S Audit (rework Time in Savings in sec/day Audit
(Rework in sec/day) (Rework in
sec/day) hrs/day)
150 50 100 0.041666667
ort - Standardisation ( Tool consumptions cost reduced)

Before 6S
Before 6S Audit After 6S Audit Audit
(Rework time in (Rework Time in Savings in sec/day (Rework
Sec /day) sec/day) time in
hrs/day)
25200 7200 18000 7
25200 7200 18000 7

10800 3600 7200 3
14400 7200 7200 4
NS NS NS NS
75600 25200 50400 21

lculation ( =12500/30/8)= ₹52.08)
After 6S Audit
(searching Savings in hrs/day Cost per day Cost per month
Time in
hrs/day)
0.0666666667 0.033333333333 1.736 45.136
0.05 0.05 2.604 67.704
0.0222222222 0.044444444444 2.31466666667 60.18133333
0.0333333333 0.033333333333 1.736 45.136
0.0125 0.0125 0.651 16.926

0.0333333333 0.033333333333 1.736 45.136
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704

0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704
0.05 0.05 2.604 67.704

0.05 0.05 2.604 67.704
0.05 0.15 7.812 203.112
0.0055555556 0.011111111111 0.57866666667 15.04533333
0.0022222222 0.001111111111 0.05786666667 1.504533333
0.0166666667 0.016666666667 0.868 22.568
0.0011111111 0.002222222222 0.11573333333 3.009066667
0.8936111111 0.988055555556 51.4579333333 1337.906267
lculation ( =12500/30/8)= ₹52.08)

After 6S Audit
(Tool handlingSavings in hrs/day Cost per day Cost per month
Time in
hrs/day)
0.0166666667 0.016666666667 0.868 22.568
0.0833333333 0.083333333333 4.34 112.84
0 0.166666666667 8.68 225.68
0.1 0.266666666667 13.888 361.088
calculation ( =12500/30/8)=50 ₹)
After 6S Audit
(rework Time Savings in hrs/day Cost per day Cost per month
in hrs/day)
0.0138888889 0.027777777778 1.44666666667 37.61333333
lculation ( =12500/30/8)= ₹52.08)
After 6S Audit
(Rework TimeSavings in hrs/day Tools Cost savings cost
in hrs/day)
2 5 500 760.4
2 5 500 760.4
1 2 500 604.16
2 2 500 604.16
NS NS 4000 750
7 14 6000 2729.12
Cost per year
541.632
812.448
722.176
541.632
203.112
541.632
812.448
812.448
812.448
812.448
812.448
812.448
812.448
812.448
812.448
812.448
812.448
812.448
2437.344
180.544
18.0544
270.816
36.1088
16054.8752
Cost per year
270.816
1354.08
2708.16
4333.056
Cost per year
451.36
Total Cost Savings
760.4
760.4
604.16
604.16
3250
5979.12
6S Audit Activities on Du
SL.No 6S Audit Date Report
6S Audited Department name
Number Key Activities
1 4/22/2021 2021-0260 Voucher and Logistics Sorting
3 4/22/2021 2021-0260 Voucher and Logistics Set in order

4 4/22/2021 2021-0260 Voucher and Logistics Safety
5 4/22/2021 2021-0260 Voucher and Logistics Standardisation

11 4/10/2021 2021-0258 High-end cell Safety

12 4/5/2021 2021-0257 MMD Set in order
13 4/5/2021 2021-0257 MMD Set in order
14 4/5/2021 2021-0257 MMD Set in order
16 4/5/2021 2021-0257 MMD safety



24 4/2/2021 2021-0255 Indiania safety
25 4/1/2021 2021-0253 Canteen Safety
26 4/1/2021 2021-0253 Canteen sorting

28 4/1/2021 2021-0253 canteen safety

33 3/22/2021 2021-0248 Turkey Cell safety

36 3/20/2021 2021-0247 Platinum sorting
38 3/15/2021 2021-0245 casting and M-lab Sorting

39 3/15/2021 2021-0245 casting and M-lab set in order
40 3/15/2021 2021-0245 casting and M-lab safety
41 3/17/2021 2021-0246
Seperation and spare parts sorting
42 3/17/2021 2021-0246
Seperation and spare parts set in order
43 3/17/2021 2021-0246
Seperation and spare parts safety
44 3/13/2021 2021-0244 wax sorting

45 3/13/2021 2021-0244 wax set in order
47 3/10/2021 2021-0243 customer cell set in order


51 3/3/2021 2021-0240 Fire Assy sorting
53 3/3/2021 2021-0240 Fire Assy safery


59 2/22/2021 2021-0238 fusion sorting

62 2/22/2021 2021-0238 fusion safety

63 2/19/2021 2021-0237 Imprez sorting
65 2/17/2021 2021-0236 QA set in order
66 2/17/2021 2021-0236 QA set in order


Problem Description Issues/Risk scale UOM

papers are Stored in the work space occupied 8X12'' Square Feet

Paper waste and Tag 5kgs Paper and 10
papers are Stored in the work Files are Waste files Kgs and Numbers
Files are not stored in proper

location and there is no searching Time is
numbering , Indexing system in high 3min min
files
glass partitions are damaged
due to weak basement and 4
severity is high - it
medicines are not there in first will lead some one is NS NS
aid box, the entry passage for
fall from height.
fire extinguishers and first aid
box are blocked
around 80 tag files are stored in

the department for future use
but it is currently not in use and Inventory cost is high
their monthly inventry ratios are and space occupaied 1X2" square feet
very high according to their
indent
unnecessary materials like box,

water battles are stored in the
Materials waste and
department (one full wooden space occupied 8X2" square feet
racks are unnecessary
materials)
materials are improperly stored searching Time is
2min min
in the racks with out any labels high
since 6 days, Rubber mats are Rubber mats waste 6 Number

stored in red tag area (Resource waste)
consumables stock register not Inventory cost is high NS Rs

maintained
Tool consumptions are high,and

Tool life is not monitored in the Inventory is high and NS Rs
resource waste
department
Unnecessary
around 4 medicines are not Inventory for
there in first aid box. medicines and health NS Rs
issues
Used tools are not stored searching Time is
properly in the allocated high and Tools 15 sec sec
Location missing
path ways access to tool Tool handling time is

1min min
handling was blocked high
Input and output location not Rework occurs due 15sec sec
allocated for process to parts mixup
Tools check list and

spending cost for
maintenance check lists are not NS Rs
updated tool is high
non access to
emergency path
emergency path ways are ways causes illness NS NS
blocked to property and
health during
accidents
Tools are not properly Labelled
and stored in its allocated Tools handling time
1min min
location. (opening draw and is high
taking dies)
around 6 to 10 materials are

found non usable in department materials waste 6 item tray and files numbers
stocks are not defined for Inventory cost is high NS Rs

production
2 chairs are not used and it is

materials waste 2 numbers
kept in red tag area
Tools are not properly stored Tool searching Time
and labelled in allocated 1min min
is high
location
preventive maintenance not Maintenance cost

done for soldering machine and time is high NS Rs
Tools and consumables usage is

Inventory cost is high NS Rs
high
safety equipments and illness occurs to
emergency exits path ways are health and property NS NS
blocked during accidents
spider web noticed in canteen

and foods are kept in open health issues NS NS
condition
non used materials are kept in

materials waste 4 numbers
canteen (empty boxes)

materials searching
stored and neither labelled in its Time is high 10sec sec
allocated location.
fire extinguishers path ways are
blocked and PPE 's are stored in health issues NS NS
foods packets
2 chairs and one wooden rack,

2 motors are stored in red tag Materials waste 2 chairs, 1 rack, 2 numbers
motors
area
consumables are stagnant

searching Time is
improperly in racks which are high and inventory 1min min
non usable and stock register cost is high
not maintained
materials are nor properly

Tool searching Time
stored and neither labelled in its is high 1min min
allocated location.
non used items like 5 item tray
and 2 wooden draw and 10 2 draw, 5 item tray,
Materials waste numbers
acrylic sheets are kept in work 10 acrylic sheets
area
fire extinguishers path ways

blocked and expired medicines health issues NS NS
are kept in the first aid box

and chairs, stone box and steel wooden rack, stone
Materials waste box, steel box-1 and numbers
boxes are kept in the chairs-2
department
Tools and materials are not
searching Time is
properly Labelled and stored in high 1min min
allocated location

papers and non used 3 steel space occupied and 8X4" square feet
boxs are kept in the materials waste
department
tools, dies, materials are nor

searching Time is
properly stored and neither 1min min
labelled in its allocated location. high
buffing motor and chairs are materials waste 1 buffing motor and numbers
kept in red tag area chair
searching Time is
properly stored and neither high 1min min
labelled in its allocated location.
plaster of paris powder wastes health issues and NS NS

are accumulated the work area resources waste
non used items like 5 rubber 5 rubber mats, chair,

mats, chair, steel box, item trays materials waste 2 item trays, 2 steel numbers
are kept in the department boxs
materials are not properly searching Time is 1 min min
Labelled and stored in the high
allocated location with register
workers are facing skin alergy

due to chemical contamination health issues NS NS
non used 6 chairs are kept in

the AHU room materials waste 6 chairs numbers
dies, tools, materials are not
properly Labelled and stored in searching Time is
the allocated location with high 1min min
register
non used items like 6 item

6 item tray, 3
trays , 3 lamps, one chair,3 steel materials waste lamps,chair,3 steel numbers
box are improperly stored in
box
department
tools and materials are not

searching Time is
properly Labelled and stored in 1 min min
the allocated location high
3 chairs, 6 lamps, 4
lamps, 4 steel boxs are kept in materials waste steel box numbers
the department
Dust collectors are kept in open

condition due to heavy
vibration, there fore dust not dust contaminated NS NS
collected properly in and
around sorroundings

searching Time is
properly Labelled and stored in high 1min min
the allocated location
non used boxes and Files, cans,
steel boxs are kept in the space occupied and 8X4" square feet
materials waste
department

searching Time is
properly Labelled and stored in high 1 min min
its allocated location
PPE's are not stored properly in

its allocated location and health issues NS NS
workers are not wearing the
PPE's properly.
non used items like 20 rubber space occupied and 20 rubber mats, one
mats, one wooden rack, 5 item materials can be wooden rack,5 item
numbers
trays, one magnetic board are used to some other tray,one magnetic
stored in the red tag area works board
Doing sealing works on papers

is repeated task and paper work handling time 30 sec sec
consumption is high
Inventory stocks consumption is inventory cost is high NS NS

high
Labelled and stored in the searching Time is 1 min min
high
allocated location
cutting-tools life not monitored

and worn tools are not re-used tools waste NS NS
unnecessary materials like

plastic box, key board, wooden Materials can be plastic box -2,
used to some other wooden draw-1,key numbers
draw are kept in the
works board-1
department
files are not properly Labelled searching Time is
and stored in the allocated 1 min min
high
location

searching Time is
properly Labelled and stored in 1 min min
high
the allocated location
fire extinguishers and

emergency exits path ways health issues due to
wastes are not NS NS
blocked and wastes are not
collected properly collected
un necessary materials like one
phone and other un specified space occupied 8X4" square feet
materials are stored in the
department
dies are stored in very height

location and it's improperly searching Time is
2 min min
labelled and stored in the high
allocated location
files are not properly Labelled

searching Time is
and stored in its allocated high 30 sec sec
location
numbering system not properly searching Time is

implemented for lights high 3 sec sec
searching Time is
Labelled and stored in its 30 sec sec
high
allocated location
numbering system not properly searching Time is

implemented for lights high 3 sec sec
Cost Analysis Report
Solutions opportunities scale Savings
unnecessary files and old papers

Space Saving 4x6" 4X6" square feet
are removed from the work area
All paper wastes are shredded and 1kg shredded

waste Reduction 1kg shredded papper
it is handover to stores for sales. and Cost saving paper and 10 and 10 tag files
Used tag files are reused. tag files
All files are labelled and it is

properly stored in allocated Searching time
location with easily accessible to reduced 1min 2 min saving
everyone.
Accident and (property damage+
Damaged partitions to be rectified illness time and NS accident time+
hospital cost production hrs
saving stoppage)

handover to stores and the
Inventory stock register to be Inventory cost is
maintained and monitored in the low and space 1X2 " 1X2" square feet
department for avoiding saving
unnecessary investment on
inventory
unnecessary material quality should 8*2" square feet and

be checked and it should be Space saving 8x2" (Rack cost) + (material
handovered to stores. cost)
materials should be placed in racks searching Time
1min 1min saving
with proper location and labels reduced
Rubber mats can be used to some Resources reused 6 600

department
unnecessary
consumables stock register to be investment on
maintained in the department for inventory cost is low NS inventory + materials
avoiding unnecessary inventory delay time+waste
reduction
Tool life need to be fixed and monitored

inventory cost is low NS tool purchase cost+
rework cost
unnecessary
unnecessary
Demand raising for medicines Inventory get
should be reviewed by OHC center reduced and no NS investment on
inventory+ waste
health issues
after usage the Tools should be
placed in allocated location and the searching Time 5sec 10 sec
reduced
tools check list should be followed
pathways access to tool handling tool handling time

30 sec 30 sec
should be free from blockages is high
Designate a place for input and Rework time get 5sec 10 sec
output to the process reduced
unnecessary
Tool life need to be monitored and investment on
inventory cost is
consumables and maintenance NS inventory + materials
record should be updated low delay time+waste
reduction
blocked emergency path ways need Health and NS time to clear pathways
to be cleared property damage in emergency time
seperate location allocated for tools
Tool handling
storage handlings with marking and 30sec 30 sec
labelling time reduced
materials waste 6 item tray and

non used materials to be handover to stores 6 item tray and files
reduced files
stocks are need to be defined and Inventory cost is NS materials delay time+
monitored reduced rework time
non used chair to be handover to materials waste

2 2 chairs
stores reduced
Tools are properly stored and Tool searching
30sec 30 sec
labelled in allocated location Time reduced
Maintenance cost materials repair cost+

Preventive maintenance should be
properly maintained and Time get NS production stoppage
reduced for fixing new meters
unnecessary
Tools and consumables stock
register to be maintained and cost Inventory cost investment on
NS inventory + materials
per each items should be displayed reduced
in the department delay time+waste
reduction
walk ways access to the safety no illness to
time to clear pathways
equipment and emergency exits property and NS
in emergency time
should be free from blockages health
it leads food poison

cleaning should be done properly ( medical expenses +
with updating the cleaning check no health issues NS food waste+ resources
sheet waste(production
time)
materials can used to some other materials waste

4 4 empty boxes
works reduced
materials are properly Labelled and

searching Time
stored in its allocated location with reduced 5sec 5 sec
its stock register
fire extinguishers path ways are free
from blockages and Seperate time to clear pathways
no health issues NS
location to be provided for storing in emergency time
PPE's
materials can used to some other materials waste 2 chairs, 1 rack,2 chairs, 1 rack, 2 motors
works reduced 2 motors
materials can properly stored and

labelled in allocated location with searching Time 30 sec 30 sec
register reduced

searching Time
labelled in allocated location with reduced 30 sec 30 sec
register
2 draw, 5 item
materials can used to some other materials waste 2 draw, 5 item tray, 10
tray, 10 acrylic
works reduced sheets acrylic sheets
fire extinguishers path ways should

be free from blockages and first aid time to clear pathways
no health issues NS
check list should be followed in emergency time
carefully
wooden rack,
materials can used to some other materials waste stone box, steel wooden rack, stone
box, steel box-1 and
works reduced box-1 and chairs-2
chairs-2
searching Time
stored in its allocated location with reduced 30 sec 30 sec
its stock register
materials can used to some other space saving 8X4" 8X4"

works

searching Time
labelled in allocated location with 30 sec 30 sec
register reduced
materials can used to some other materials waste 1 buffing motor1 buffing motor and chair
works reduced and chair
searching Time
register
if wastes are not

collected properly
wastes to be handover to RF &RC
( cleaning time +
properly and their PoP no health issues NS production stoppage
consumptions is very high, there
fore can reuse the waste again. due to cleaning+
workers illness
(medical expenses ))
5 rubber mats,
materials can used to some other materials waste chair, 2 item 5 rubber mats, chair, 2
works reduced trays, 2 steel item trays, 2 steel boxs
boxs
stored in its allocated location with searching Time 30 sec 30 sec
reduced
its stock register
available PPE 's quality to be production stoppage

reviewed and chemical due to chemical
compatibility matrix and chemical
usage percentage to be evaluated. no health issues NS spillage ( cleaning time
+ medical expenses to
and use other related chemicals for
avoiding skin alergies to workers workers)

works reduced 6 chairs 6 chairs
searching Time
register
6 item tray, 3
materials can used to some other materials waste lamps,chair,3 6 item tray, 3
works reduced lamps,chair,3 steel box
steel box

searching Time
stored in its allocated location with 30 sec 30 sec
its stock register reduced
3 chairs, 6
works reduced lamps, 4 steel3 chairs, 6 lamps, 4 steel box
box
vibration and sound level need to

measure and reduce, dust collectors no dust NS accident time+
are properly kept in closed contaminated production stoppage
condition

searching Time
its stock register
un necessary materials should be space saving 8x4" 8*4"
removed from the work area

searching Time is
its stock register
PPE 's quality should be reviewed no health issues NS accident time

and changed
20 rubber mats,
unnecessary materials kept in the materials waste one wooden 20 rubber mats, one
reduced and wooden rack,5 item
department to be handover to rack,5 item
stores inventory cost tray,one tray,one magnetic
controlled board
magnetic board
seal contents to be printed in job work handling

cards and use. contents in papers time reduced and
should be reviewed because lot of sealing work 0 sec 30 sec
paper wasted due to content not process on
properly filled in papers papers eliminated
unnecessary
investment on
inventory stock register should be unnecessary NS inventory + materials
maintained and updated stocks can reduce
delay time+waste
reduction
stored in its allocated location with searching Time 30sec 30 sec
reduced
its stock register
unnecessary
worn cutting tools are reused with tool investment on
the help of grinding work consumptions NS inventory + materials
reduced delay time+waste
reduction
materials can be used to some other materials waste plastic box -2, plastic box -2, wooden
wooden draw-
works reduced draw-1,key board-1
1,key board-1
files are properly Labelled and searching Time
30 sec 30 sec
stored in the allocated location reduced
tools and materials are properly

searching Time
Labelled and stored in the allocated 30 sec 30 sec
reduced
location
if wastes are not

collected properly
safety
fire extinguishers and emergency equipments ( cleaning time +
exits path ways are free from NS production stoppage
handling time
blockages reduced due to cleaning+
workers illness
(medical expenses ))
unnecessary materials stored the space saving 8X4" 8*4"
department to be removed
dies are properly Labelled and searching Time

30 sec 30 sec
stored in its allocated location reduced

stored in the allocated location reduced 10 sec 20 sec
numbering system to be searching Time

implemented reduced 1sec 2 sec
materials are properly Labelled and searching Time
15 sec 15 sec
stored in its allocated location reduced

implemented reduced 1sec 2 sec
on After 6S Audit
Cost Saving Per Day Cost Saving Per Month Cost Saving Per year
960 960 960
16 16 16
3.33333333333333 86.6666666666667 1040

(if glass damaged (glass (if glass damaged (glass (if glass damaged (glass
purchase cost (100₹/glass) + purchase cost (100₹/glass) purchase cost (100₹/glass) +
glass fitting cost (50₹/hr)) + glass fitting cost (50₹/hr)) glass fitting cost (50₹/hr))
+production stoppage due to +production stoppage due +production stoppage due to
man (50₹/hr) + ( medical to man (50₹/hr) + man (50₹/hr) + ( medical
allowances) ( medical allowances) allowances)
80 80 80
1556.66666666667 1556.66666666667 1556.66666666667

5 130 1560
600 600 600
unnecessary investment
unnecessary investment on unnecessary investment on
inventory + materials delay on inventory + materials inventory + materials delay
delay time+waste
time+waste reduction reduction time+waste reduction
tool purchase cost+ rework tool purchase cost+ rework tool purchase cost+ rework
cost cost cost
unnecessary investment on unnecessary investment unnecessary investment on

inventory+ waste on inventory+ waste inventory+ waste
4.44444444444444 115.555555555556 1386.66666666667
1.66666666666667 43.3333333333333 520
0.0555555555555556 72.2222222222222 866.666666666666
unnecessary investment on unnecessary investment unnecessary investment on

on inventory + materials
inventory + materials delay inventory + materials delay
time+waste reduction delay time+waste time+waste reduction
reduction
time to clear pathways in time to clear pathways in time to clear pathways in

emergency time emergency time emergency time
4.16666666666667 50 600
1240 1240 1240
waiting for the data waiting for the data waiting for the data
1333.33333333333 1333.33333333333 1333.33333333333

1.66666666666667 43.3333333333333 520
materials repair cost+ materials repair cost+ materials repair cost+

production stoppage for production stoppage for production stoppage for fixing
fixing new meters fixing new meters new meters
unnecessary investment on on inventory + materials unnecessary investment on
inventory + materials delay inventory + materials delay
delay time+waste
it leads food poison it leads food poison it leads food poison ( medical
( medical expenses + food ( medical expenses + food expenses + food waste+
waste+ resources waste+ resources resources waste(production
waste(production time) waste(production time) time)
533.333333333333 533.333333333333 533.333333333333
0.625 16.25 195

4500 4500 4500
3.33333333333333 86.6666666666667 1040
5 130 1560
766.666666666667 766.666666666667 766.666666666667

1233.33333333333 1233.33333333333 1233.33333333333

5 130 1560
1280 1280 1280
5 130 1560
3000 3000 3000

5 130 1560
if wastes are not collected if wastes are not collected if wastes are not collected
properly ( cleaning time + properly ( cleaning time + properly ( cleaning time +
production stoppage due to production stoppage due production stoppage due to
cleaning+ workers illness to cleaning+ workers cleaning+ workers illness
(medical expenses )) illness (medical expenses )) (medical expenses ))
1350 1350 1350

5 130 1560

chemical spillage ( cleaning to chemical spillage chemical spillage ( cleaning
time + medical expenses to ( cleaning time + medical time + medical expenses to
workers) expenses to workers) workers)
10925 10925 10925

5 130 1560
2050 2050 2050
5 130 1560
2400 2400 2400
accident time+ production accident time+ production accident time+ production

stoppage stoppage stoppage
5 130 1560
1280 1280 1280
5 130 1560
accident time accident time accident time

4000 4000 4000
16.6666666666667 433.333333333333 5200
unnecessary investment on unnecessary investment on
inventory + materials delay on inventory + materials inventory + materials delay
delay time+waste
5 130 1560
unnecessary investment on on inventory + materials unnecessary investment on
inventory + materials delay delay time+waste inventory + materials delay
time+waste reduction time+waste reduction
reduction
516.666666666667 516.666666666667 516.666666666667

5 130 1560
5 130 1560
if wastes are not collected if wastes are not collected if wastes are not collected
properly ( cleaning time + properly ( cleaning time + properly ( cleaning time +
cleaning+ workers illness to cleaning+ workers cleaning+ workers illness
(medical expenses )) illness (medical expenses )) (medical expenses ))
1280 1280 1280
15 390 4680
0.555555555555556 14.4444444444444 173.333333333333
0.111111111111111 2.88888888888889 34.6666666666667

1.66666666666667 43.3333333333333 520
0.111111111111111 2.88888888888889 34.6666666666667

Activities on During 6S Audi
SL.No 6S Audit Date 6S Audit Report Number 6S Audited Department name
Key Activities
3 4/22/2021 2021-0260 Voucher and Logistics Set in order

4 4/22/2021 2021-0260 Voucher and Logistics Safety
5 4/22/2021 2021-0260 Voucher and Logistics Standardisation


11 4/10/2021 2021-0258 High-end cell Safety
12 4/5/2021 2021-0257 MMD Set in order
13 4/5/2021 2021-0257 MMD Set in order
14 4/5/2021 2021-0257 MMD Set in order

16 4/5/2021 2021-0257 MMD safety


24 4/2/2021 2021-0255 Indiania safety
25 4/1/2021 2021-0253 Canteen Safety

26 4/1/2021 2021-0253 Canteen sorting
28 4/1/2021 2021-0253 canteen safety

33 3/22/2021 2021-0248 Turkey Cell safety

36 3/20/2021 2021-0247 Platinum sorting

38 3/15/2021 2021-0245 casting and M-lab Sorting
39 3/15/2021 2021-0245 casting and M-lab set in order

40 3/15/2021 2021-0245 casting and M-lab safety
41 3/17/2021 2021-0246 Seperation and spare parts sorting
42 3/17/2021 2021-0246 Seperation and spare parts set in order

43 3/17/2021 2021-0246 Seperation and spare parts safety
44 3/13/2021 2021-0244 wax sorting
45 3/13/2021 2021-0244 wax set in order

47 3/10/2021 2021-0243 customer cell set in order

51 3/3/2021 2021-0240 Fire Assy sorting

53 3/3/2021 2021-0240 Fire Assy safety


59 2/22/2021 2021-0238 fusion sorting

62 2/22/2021 2021-0238 fusion safety
63 2/19/2021 2021-0237 Imprez sorting

65 2/17/2021 2021-0236 QA set in order
66 2/17/2021 2021-0236 QA set in order

vities on During 6S Audit Activities on After 6
Problem Description Solutions opportunities scale

papers are Stored in the unnecessary files and old papers Space Saving 4x6"
work area which are not are removed from the work area
needed
last 10 years old files and All paper wastes are shredded and waste 1kg shredded
papers are Stored in the
work area which are not it is handover to stores for sales. Reduction and paper and 10
Used tag files are reused. Cost saving tag files
needed
Files are not stored in proper All files are labelled and it is
location and there is no properly stored in allocated Searching time
numbering , Indexing system location with easily accessible to reduced 1min
in files everyone.
glass partitions are damaged
due to weak basement and 4 Accident and
medicines are not there in illness time and
Damaged partitions to be rectified
first aid box, the entry hospital cost
passage for fire extinguishers saving
and first aid box are blocked

around 80 tag files are handover to stores and the
stored in the department for
Inventory stock register to be Inventory cost
future use but it is currently maintained and monitored in the is low and space 1X2 "
not in use and their monthly
department for avoiding saving
inventry ratios are very high
according to their indent unnecessary investment on
inventory

box, water battles are stored unnecessary material quality should
in the department (one full be checked and it should be Space saving 8x2"
wooden racks are handovered to stores.
unnecessary materials)
materials are improperly
materials should be placed in racks searching Time
stored in the racks with out with proper location and labels reduced 1min
any labels
since 6 days, Rubber mats Rubber mats can be used to some Resources reused 6
are stored in red tag area department
consumables stock register consumables stock register to be

maintained in the department forinventory cost is low
not maintained
avoiding unnecessary inventory
Tool consumptions are

high,and Tool life is not
Tool life need to be fixed and monitored
inventory cost is low
monitored in the
department
unnecessary
around 4 medicines are not Demand raising for medicines Inventory get
there in first aid box. should be reviewed by OHC center reduced and no
health issues
Used tools are not stored after usage the Tools should be searching Time
properly in the allocated placed in allocated location and the 5sec
reduced
Location tools check list should be followed
path ways access to tool pathways access to tool handling tool handling
handling was blocked should be free from blockages time is high 30 sec
Input and output location Designate a place for input and Rework time 5sec
not allocated for process output to the process get reduced
Tools check list and Tool life need to be monitored and
inventory cost
maintenance check lists are consumables and maintenance
not updated record should be updated is low
Health and
emergency path ways are blocked emergency path ways need
blocked to be cleared property
damage
Tools are not properly

seperate location allocated for tools
Labelled and stored in its storage handlings with marking and Tool handling 30sec
allocated location. (opening time reduced
labelling
draw and taking dies)
around 6 to 10 materials are materials waste 6 item tray and

found non usable in non used materials to be handover to stores
reduced files
department
stocks are not defined for stocks are need to be defined and Inventory cost
production monitored is reduced
2 chairs are not used and it non used chair to be handover to materials waste
2
is kept in red tag area stores reduced
Tools are not properly stored

and labelled in allocated Tools are properly stored and Tool searching 30sec
labelled in allocated location Time reduced
location
Maintenance
preventive maintenance not Preventive maintenance should be cost and Time 200
done for soldering machine properly maintained
get reduced
Tools and consumables stock
Tools and consumables register to be maintained and cost Inventory cost
usage is high per each items should be displayed reduced
in the department
safety equipments and walk ways access to the safety no illness to

emergency exits path ways equipment and emergency exits property and
are blocked should be free from blockages health
spider web noticed in cleaning should be done properly

canteen and foods are kept with updating the cleaning check no health issues
in open condition sheet
non used materials are kept materials can used to some other materials waste
4
in canteen (empty boxes) works reduced
materials are not properly materials are properly Labelled and searching Time
stored and neither labelled stored in its allocated location with 5sec
reduced
in its allocated location. its stock register
fire extinguishers path ways fire extinguishers path ways are free
from blockages and Seperate
are blocked and PPE 's are no health issues
stored in foods packets location to be provided for storing
PPE's
2 chairs and one wooden

materials can used to some other materials waste 2 chairs, 1 rack,
rack, 2 motors are stored in works reduced 2 motors
red tag area
consumables are stagnant
improperly in racks which materials can properly stored and searching Time
labelled in allocated location with 30 sec
are non usable and stock reduced
register not maintained register
materials are nor properly materials can properly stored and

stored and neither labelled labelled in allocated location with searching Time 30 sec
reduced
in its allocated location. register
non used items like 5 item 2 draw, 5 item

tray and 2 wooden draw and materials can used to some other materials waste
tray, 10 acrylic
10 acrylic sheets are kept in works reduced sheets
work area
fire extinguishers path ways fire extinguishers path ways should

blocked and expired be free from blockages and first aid
no health issues
medicines are kept in the check list should be followed
first aid box carefully
non used item of wooden wooden rack,
racks and chairs, stone box materials can used to some other materials waste stone box, steel
and steel boxes are kept in works reduced box-1 and
the department chairs-2
Tools and materials are not materials are properly Labelled and
searching Time
properly Labelled and stored stored in its allocated location with reduced 30 sec
in allocated location its stock register

papers and non used 3 steel materials can used to some other space saving 8*4"
boxs are kept in the works
department
properly stored and neither labelled in allocated location with searching Time 30 sec
labelled in its allocated reduced
location. register
buffing motor and chairs are materials can used to some other materials waste 1 buffing motor
kept in red tag area works reduced and chair

properly stored and neither labelled in allocated location with searching Time 30 sec
labelled in its allocated reduced
register
location.
wastes to be handover to RF &RC
plaster of paris powder properly and their PoP
wastes are accumulated the no health issues
work area consumptions is very high, there
fore can reuse the waste again.
non used items like 5 rubber 5 rubber mats,

mats, chair, steel box, item materials can used to some other materials waste chair, 2 item
trays are kept in the works reduced trays, 2 steel
department boxs

materials are not properly materials are properly Labelled and
Labelled and stored in the stored in its allocated location with searching Time 30 sec
reduced
allocated location with its stock register
register
available PPE 's quality to be
reviewed and chemical
workers are facing skin
alergy due to chemical compatibility matrix and chemical no health issues
usage percentage to be evaluated.
contamination
and use other related chemicals for
avoiding skin alergies to workers
non used 6 chairs are kept in materials can used to some other materials waste
the AHU room works reduced 6 chairs
dies, tools, materials are not

properly Labelled and stored labelled in allocated location with searching Time 30 sec
in the allocated location with reduced
register
register
non used items like 6 item 6 item tray, 3
trays , 3 lamps, one chair,3 materials can used to some other materials waste
lamps,chair,3
steel box are improperly works reduced
stored in department steel box
tools and materials are not materials are properly Labelled and searching Time
properly Labelled and stored stored in its allocated location with 30 sec
reduced
in the allocated location its stock register
non used items like 3 chairs, 3 chairs, 6

6 lamps, 4 steel boxs are materials can used to some other materials waste lamps, 4 steel
works reduced
kept in the department box
Dust collectors are kept in vibration and sound level need to
open condition due to heavy
measure and reduce, dust collectors no dust
vibration, there fore dust not
are properly kept in closed contaminated
collected properly in and condition
around sorroundings
reduced
in the allocated location its stock register
non used boxes and Files,

un necessary materials should be
cans, steel boxs are kept in space saving 8x4"
removed from the work area
the department
is reduced
in its allocated location its stock register
PPE's are not stored properly

in its allocated location and PPE 's quality should be reviewed no health issues
workers are not wearing the and changed
PPE's properly.
non used items like 20 20 rubber mats,

materials waste
rubber mats, one wooden unnecessary materials kept in the one wooden
rack, 5 item trays, one department to be handover to reduced and rack,5 item
inventory cost
magnetic board are stored in stores controlled tray,one
the red tag area magnetic board
work handling
seal contents to be printed in job time reduced
Doing sealing works on cards and use. contents in papers
and sealing
papers is repeated task and should be reviewed because lot of work process 0 sec
paper consumption is high paper wasted due to content not
on papers
properly filled in papers eliminated
Inventory stocks inventory stock register should be unnecessary

stocks can
consumption is high maintained and updated
reduce
materials are not properly materials are properly Labelled and searching Time
Labelled and stored in the stored in its allocated location with 30sec
reduced
allocated location its stock register
cutting-tools life not worn cutting tools are reused with tool
monitored and worn tools consumptions
the help of grinding work
are not re-used reduced

plastic box -2,
plastic box, key board, materials can be used to some other materials waste wooden draw-
wooden draw are kept in the works reduced
department 1,key board-1
files are not properly

Labelled and stored in the stored in the allocated location reduced 30 sec
allocated location
tools and materials are not tools and materials are properly searching Time
properly Labelled and stored Labelled and stored in the allocated 30 sec
in the allocated location location reduced
fire extinguishers and safety

fire extinguishers and emergency
emergency exits path ways exits path ways are free from equipments
blocked and wastes are not handling time
blockages
collected properly reduced
un necessary materials like

one phone and other un unnecessary materials stored the space saving 8X4"
specified materials are department to be removed
stored in the department
dies are stored in very height
location and it's improperly dies are properly Labelled and searching Time 30 sec
labelled and stored in the stored in its allocated location reduced
allocated location
files are not properly

Labelled and stored in its files are properly Labelled and searching Time 10 sec
stored in the allocated location reduced
allocated location

properly implemented for numbering system to be searching Time 1sec
implemented reduced
lights

materials are properly Labelled and searching Time
Labelled and stored in its stored in its allocated location reduced 15 sec
allocated location
properly implemented for 1sec
lights implemented reduced
Savings Cost Saving Per Day Cost Saving Per Month Cost Saving Per year
4X6" square feet 960 960 960
1kg shredded papper

and 10 tag files 16 16 16
2 min saving 3.33333333333333 86.6666666666667 1040

(if glass damaged (glass (if glass damaged (glass
(if glass damaged (glass
purchase cost (100₹/glass) purchase cost
(property damage+ purchase cost (100₹/glass)
accident time+ + glass fitting cost (100 ₹/glass) + glass + glass fitting cost (50₹/hr))
(50₹/hr))+production fitting cost (50₹/hr))
production hrs +production stoppage due
stoppage) stoppage due to man +production stoppage to man (50₹/hr) + ( medical
(50₹/hr) + ( medical due to man (50₹/hr) + (
allowances) medical allowances) allowances)
1X2" square feet 80 80 80
8*2" square feet and

(Rack cost) + (material 1556.66666666667 1556.66666666667 1556.66666666667
cost)
1min saving 5 130 1560
600 600 600 600
unnecessary unnecessary
investment on on inventory + materials investment on unnecessary investment on
inventory + materials inventory + materials inventory + materials delay
delay time+waste
delay time+waste reduction delay time+waste time+waste reduction
reduction reduction
tool purchase cost+

rework cost+ tool purchase cost+ tool purchase cost+ tool purchase cost+ rework
production stoppage+ rework cost rework cost cost
tool setting time
investment on unnecessary investment investment on unnecessary investment on
on inventory+ waste inventory+ waste
inventory+ waste inventory+ waste
10 sec 4.44444444444444 115.555555555556 1386.66666666667
30 sec 1.66666666666667 43.3333333333333 520
10 sec 0.0555555555555556 1.44444444444444 17.3333333333333

investment on unnecessary investment investment on unnecessary investment on
on inventory + materials
delay time+waste delay time+waste delay time+waste time+waste reduction
reduction
reduction reduction
time to clear pathways time to clear pathways in time to clear pathways time to clear pathways in
in emergency time emergency time in emergency time emergency time
30 sec 4.16666666666667 50 600
6 item tray and files 1240 1240 1240

materials delay time+
rework time waiting for the data waiting for the data waiting for the data
2 chairs 1333.33333333333 1333.33333333333 1333.33333333333
30 sec 1.66666666666667 43.3333333333333 520
materials repair cost+ materials repair cost+ materials repair cost+ materials repair cost+
production stoppage production stoppage for production stoppage production stoppage for
for fixing new meters fixing new meters for fixing new meters fixing new meters
delay time+waste
reduction reduction
it leads food poison

it leads food poison it leads food poison it leads food poison
( medical expenses +
( medical expenses + food ( medical expenses + ( medical expenses + food
food waste+ resources waste+ resources food waste+ resources waste+ resources
waste(production
time) waste(production time) waste(production time) waste(production time)
4 empty boxes 533.333333333333 533.333333333333 533.333333333333
5 sec 0.625 16.25 195
2 chairs, 1 rack, 2 motors 4500 4500 4500

30 sec 3.33333333333333 86.6666666666667 1040
30 sec 5 130 1560
2 draw, 5 item tray, 10

766.666666666667 766.666666666667 766.666666666667
acrylic sheets
wooden rack, stone
box, steel box-1 and 1233.33333333333 1233.33333333333 1233.33333333333
chairs-2
30 sec 5 130 1560
8X4" 1280 1280 1280

30 sec 5 130 1560
1 buffing motor and chair 3000 3000 3000
30 sec 5 130 1560

if wastes are not if wastes are not
if wastes are not collected
collected properly collected properly if wastes are not collected
properly ( cleaning time +
( cleaning time + production stoppage due ( cleaning time + properly ( cleaning time +
production stoppage production stoppage production stoppage due
due to cleaning+ to cleaning+ workers due to cleaning+ to cleaning+ workers
illness (medical
workers illness workers illness illness (medical expenses ))
expenses ))
(medical expenses )) (medical expenses ))
5 rubber mats, chair, 2

item trays, 2 steel 1350 1350 1350
boxs
30 sec 5 130 1560

production stoppage production stoppage
production stoppage due production stoppage due
due to chemical due to chemical
spillage ( cleaning time to chemical spillage spillage ( cleaning time to chemical spillage
( cleaning time + medical ( cleaning time + medical
+ medical expenses to + medical expenses to
workers) expenses to workers) workers) expenses to workers)
6 chairs 10925 10925 10925
30 sec 5 130 1560

6 item tray, 3
2050 2050 2050
lamps,chair,3 steel box
30 sec 5 130 1560
3 chairs, 6 lamps, 4 steel box 2400 2400 2400

accident time+ accident time+ production accident time+ accident time+ production
production stoppage stoppage production stoppage stoppage
30 sec 5 130 1560
8*4" 1280 1280 1280

30 sec 5 130 1560
accident time accident time accident time accident time
20 rubber mats, one

wooden rack,5 item 4000 4000 4000
tray,one magnetic
board
30 sec 16.6666666666667 433.333333333333 5200
delay time+waste
reduction reduction
30 sec 5 130 1560

delay time+waste
delay time+waste delay time+waste time+waste reduction
reduction reduction reduction
plastic box -2, wooden 516.666666666667 516.666666666667 516.666666666667

draw-1,key board-1
30 sec 5 130 1560

30 sec 5 130 1560
if wastes are not if wastes are not

collected properly if wastes are not collected collected properly if wastes are not collected
properly ( cleaning time +
( cleaning time + ( cleaning time + properly ( cleaning time +
production stoppage production stoppage due production stoppage production stoppage due
to cleaning+ workers
due to cleaning+ due to cleaning+ to cleaning+ workers
workers illness illness (medical workers illness illness (medical expenses ))
expenses ))
(medical expenses )) (medical expenses ))
8*4" 1280 1280 1280

30 sec 5 130 1560
20 sec 0.555555555555556 14.4444444444444 173.333333333333
2 sec 0.111111111111111 2.88888888888889 34.6666666666667
15 sec 1.66666666666667 43.3333333333333 520

2 sec 0.111111111111111 2.88888888888889 34.6666666666667

6S Cost Analysi-Final Ok

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6S Cost Analysi-Final Ok

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6S Cost Analysis

No.of.department cost savings Cost savings Per

Tools consumption, rework time 5+ 500 tool

Total 47706 66809

last 10 years old files and

unnecessary materials like box,

old job card , unnecessary

non used boxes and Files, cans,

un necessary materials like one

around 80 tag files are stored in

unnecessary material quality Space Saving in square

materials can used to some other Space Saving in square

un necessary materials should be Space Saving in square

unnecessary materials stored the Space Saving in square 8

6S Cost Analysis Report -standardisation

tivities on After 6S Audit

3 4/22/2021 2021-0260 Voucher and Sorting

4 4/10/2021 2021-0258 High-end cell sorting

5 3/4/2021 2021-0256 CNC Bangle sorting

6 3/4/2021 2021-0256 CNC Bangle sorting

7 4/2/2021 2021-0255 Indiania sorting

8 4/1/2021 2021-0253 Canteen sorting

9 3/30/2021 2021-0252 Line cell 3 sorting

10 3/30/2021 2021-0252 Line cell 3 sorting

11 3/30/2021 2021-0252 Line cell 3 sorting

13 3/22/2021 2021-0248 Turkey Cell sorting

14 3/22/2021 2021-0248 Turkey Cell sorting

15 3/6/2021 2021-0241 stamping sorting

16 3/6/2021 2021-0241 stamping sorting

17 3/6/2021 2021-0241 stamping sorting

18 3/6/2021 2021-0241 stamping sorting

22 3/17/2021 2021-0246 Seperation and sorting

25 3/13/2021 2021-0244 wax sorting

26 3/10/2021 2021-0243 customer cell sorting

27 3/10/2021 2021-0243 customer cell sorting

28 3/10/2021 2021-0243 customer cell sorting

29 3/10/2021 2021-0243 customer cell sorting

30 3/10/2021 2021-0243 Diamond cell Sorting

31 3/10/2021 2021-0243 Diamond cell Sorting

32 3/10/2021 2021-0243 Diamond cell Sorting

33 3/1/2021 2021-0239 Handmade sorting

34 3/1/2021 2021-0239 Handmade sorting

36 3/1/2021 2021-0239 Handmade sorting

37 2/22/2021 2021-0238 fusion sorting

38 2/22/2021 2021-0238 fusion sorting

39 2/22/2021 2021-0238 fusion sorting

Materials Type Quantity Cost

Activities on During 6S Audit Materials Type

last 10 years old files and papers

last 10 years old files and papers

last 10 years old files and papers

since 6 days, Rubber mats are

around 6 to 10 materials are found

around 6 to 10 materials are found

2 chairs are not used and it is kept

non used materials are kept in

2 chairs and one wooden rack, 2

2 chairs and one wooden rack, 2

non used items like 5 item tray and

non used items like 5 item tray and

non used item of wooden racks

non used item of wooden racks

non used item of wooden racks