GRADUATION PROJECT

REPORT:

Industry: Suryalakshmi cotton mills ltd.

Mentor: Mr.Avinash kumar
HR:

• Submitted by:
• Rohan.Jatling 1
ABOUT THE INDUSTRY:

Partnering leading global brands as an original denim manufacturer,

Suryalakshmi Cotton creates value added denim garments in a variety of
styles, colours and finishes. We are a major denim wear supplier to high
street retailers, fashion houses and independent designers across the
globe, for childrenswear, womenswear and menswear. Working in close
collaboration with customers’ design teams, we cater to fast fashion
requirements with quick turnaround times.
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.

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-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
Tinting
Localized pigment spray
Grinding
Damaging
Ozone finishes
Spotting etc. 3
 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.

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Project 1:
• 5s in
• DENIM WASHING DEPARTMENT.

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 STUDY AND IMPLEMENTATION OF 5S

5s- A strategy for performance excellence

Introduction:
5S is a reference to a list of five Japanese words which 'start' with S. This list
is a mnemonic for a methodology that is often incorrectly characterized as
"standardized cleanup", however it is much more than cleanup. 5S is a
philosophy and a way of organizing and managing the workspace and work
flow with the intent to improve efficiency by eliminating waste

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 What is 5S?
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 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. In addition to the
above, another key distinction between 5S and "standardized cleanup" is
Seiton. Seiton is often misunderstood, perhaps due to efforts to translate
into an English word beginning with "S" (such as "sort" or "straighten"). 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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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.

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 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.
• 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.

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 Keys to successful 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 take 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

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 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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Methodology:
• In order to achieve high levels
of quality, safety and
productivity workers must
have a conducing
environment.
• As seen in the figures the
fabric coming from the
warehouse is placed directly
on the floor in the cutting and
spreading department.
• Several bundles of different
styles of fabrics are kept on
the ground with no systematic
arrangement of fabric styles.
• In such case sometimes the
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operators find it difficult to
find a specific style of fabric
from all those bundles.
• If tools and materials are
conveniently located in
uncluttered work areas
operators spend less time
looking for items.
• This leads to higher
workstation efficiency, a
fundamental goal in mass
production.
• The installation of racks and
tables can result smooth
working without any
deviation or obstruction in
the operator’s work. In this
way everyone will be knowing
where things are supposed to
be.
• It can increase space and 14
work area and it can also be
time saving.
 SORT
Sorting unnecessary materials in
warehouse:

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 SORT:
Sorting out the removable or
non usable materials (Plastic
polythenes, Trimmed
edges,Boxes etc.)

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Implementation of 5s:
Implementation of 5s Step by step internal audit
1. Preparation of 5s auditing
• Formation of 5s audit team • Representative from all departments.
2. Internal 5s audit training
3. Defining territorial areas
4. Setting up 5s grouping in each department
5. Develop audit criteria
• based on working area
6. Preparation of audit material
• stickers
• report writing format
• auditor tag
7. Distribution of audit criteria for each of 5s working areas 17
8. Grouping of auditor and area for auditing
 SET IN ORDER:
BEFORE AFTER

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 SET IN ORDER:
Inspection table without any Inspection table with proper
description description

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STANDARDISE:

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PP Spray Cheking table
BEFORE AFTER

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Grinding inspection table
BEFORE AFTER

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Internal training
1. weekly training
2. encouraging masses
3. generating the interest
Territorial areas
1. administrative group- getting complete daily report
2. production group-keeping watch on production
3. store group- providing all the necessary materials and tool at
workplace, proper storing of finished work piece.

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 Sustain:
-Spreading awareness on Total productive maintenance to the
workforce
-Repeating the activity periodically to sustain the improvements.

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 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.

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-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.
A clear and organized workplace with proper labeling 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 26
products during the production process.
• Worker Commitment
Achieving worker commitment is one of the major goals of
implementing 5S lean manufacturing training.
This is because the workers would be largely responsible for
using it on the ground. 5S emphasizes on worker participation
by streamlining their work and allowing them to provide
inputs to make productive changes in the overall design of the
workplace and also to carry out its maintenance tasks.

This encourages worker involvement for long-term workplace

sustainability which in turn enhances their commitment
towards work. This improvement also provides ancillary
benefits of lower absenteeism in the workplace.

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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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References:
• http://www.suryalakshmi.com/our-solutions-garments.aspx
• https://appliedperformance.ca/key-benefits-5s-process-
implementation/

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Thank you

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