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To cite this document:
Shaman Gupta Sanjiv Kumar Jain , (2015),"An application of 5S concept to organize the workplace at
a scientific instruments manufacturing company", International Journal of Lean Six Sigma, Vol. 6 Iss 1
pp. 73 - 88
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An application of 5S concept to
organize the workplace at a
scientific instruments
manufacturing company
Shaman Gupta
An application
of 5S concept
73
Received 16 August 2013
Revised 7 July 2014
Accepted 26 July 2014
1. Introduction to 5S
The 5S is the English meaning of five Japanese words which stands for Seiri (sorting),
Seiton (set in order), Seiso (sweep), Seiketsu (standardize) and Shitsuke (sustain)
(Ho et al., 1995; Ho, 1997; Vasudevan, 1998). In mid 1950s, Japan was the first country to
use the 5S approach to assist a manufacturing sector organization (Korkut et al., 2009).
Implementing 5S in the organization is one of the important steps toward continuous
improvement. Implementing 5S ensures continuous improvement in housekeeping and
results in better safety standards and environment (Ho, 1999; Mente, 1994). To start with
5S implementation, there is a need of developing a common language that is understood
by all, so that people in the organization can communicate with each other (Sethi and Pal,
IJLSS
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An application
of 5S concept
75
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Material
No proper storage
Figure 1.
Cause-and-effect
diagram for an
unorganized shop
floor
Machine
Poor keep and maintenance
Unorganized shop
floor
An application
of 5S concept
77
5S implementation
Figure 2.
Methodology
flowchart
4. 5S implementation
4.1 Sort implementation action plan
The goal is to eliminate nonessential items from the workplace. Items are red tagged
and stored in a local red-tag area for a specific period, typically five days. If not
reclaimed by the work group, items are then moved to one of the companys central-red
tag areas. Here everyone can shift through the items to see if there is anything they need.
When items have been in the central area for a specific period, the company disposes of
them through resale, donation, recycling or trash. Table I represents before-and-after
pictures of sort implementation.
4.2 Set in order implementation action plan
In set in order, team members come together and share the insights they have gained
during S1. They analyze the work area for additional improvement opportunities and
Aspect
Before
After
State
Conditions
Table I.
Sort implementation
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78
look for ways to reduce sources of waste and error as well as to make the workplace more
visually instructive. The team brainstorms potential solutions, with special emphasis on
using visual resources to achieve improvement. Be sure to get feedback and approval
from stakeholders (production, maintenance, safety, management, etc.) before making
changes. Table II represents before-and-after pictures of sort implementation.
We understand that it is not always easy to calculate savings, but this may also be a
reason that the largest obstacle in implementation is management buy-in. If we cannot
convert improvements to a rupee value, management will lose interest in implementing
the 5S system. Thus before implementing set in order activity, a time cost analysis was
performed. It was observed that workers were spending average of 30 minutes/day in
search of a tool when there was no shadow board in the making. After providing shadow
board for the tools, average time observed was only 5 minutes/day, thereby saving lots
of money. Figure 3 represents the tool searching time.
Aspect
Before
After
State
Conditions
Table II.
Set in order
implementation
Figure 3.
Tool searching time
An application
of 5S concept
79
Aspect
Before
After
State
Conditions
Table III.
Shine
implementation
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80
Table IV.
Weekly cleaning
schedule
Days
Sweeping
Garbage removal
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Mr A
Mrs B
Mr C
Mr D
Mr E
Mrs F
Mr A
Mr B
Mr C
Mr D
Mr E
Mr F
Table V.
SOP for productdead weights
SOP no: 1
An application
of 5S concept
81
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5S
SEIRI
Materials
Equipments
Connection apparatus
Visual control
Written standards
Quantity indicators
Item indicators
Location indicators
Separation lines
82
SEITON
SEISOSE
IKETSU
SHITSUKE
Table VI.
5S audit check sheet
form (of Week 6)
10
Connection apparatus
11
Machines
12
Floors
13
14
15
16
17
Cleaning
responsibility
Cleaning habit
Ventilation
Lighting
18
Working clothes
19
20
21
22
23
24
25
Procedures
Score
2 3
5S activities
(weeks)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Sort score
Set in
order score
0
0
1
3
5
7
10
12
12
12
11
11
10
5
5
5
5
11
12
12
0
0
2
2
2
5
10
11
8
8
8
7
7
6
6
6
11
11
11
11
Shine score
Standardize
score
Sustain
score
Total
score
0
1
2
5
6
6
5
7
7
7
7
6
6
3
3
4
4
8
8
8
3
2
3
7
8
8
9
8
8
8
8
8
6
6
6
10
11
13
13
13
4
6
7
9
10
10
10
11
11
11
11
11
12
12
11
11
11
11
11
11
7
9
15
26
31
36
44
49
46
46
45
43
40
31
31
36
42
54
55
55
An application
of 5S concept
83
Table VII.
5S weekly appraisal
scores
Figure 4.
Sort score variations
improvement opportunities and the charts should be placed on display in that area. The
bar chart has been shown in Figure 9. Further, one sample check sheet has been shown
of Week 6 in Table VI. 5S activities total score from Week 1 to 20 has been shown in
Table VII.
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Figure 5.
Set in order score
variations
Figure 6.
Shine score
variations
An application
of 5S concept
85
Figure 7.
Standardize score
variation
Figure 8.
Sustain score
variation
proud of my workplace. So overall they were happy from the results they achieved
after implementing the 5S system. They promised to make 5S as a habit so the
organization is benefitted from it.
6. Conclusion
The 5S event was a part of the lean initiative at the manufacturing facility. Several
changes were made to the operating procedures, tool organization, cleaning schedules
and material handling.
The first phase, sort, resulted in removing unwanted items, broken tools and
cabinets, unused parts and scrap materials. Unused inventory was returned to
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Figure 9.
Total 5S score
(Week 1 to 20)
purchasing, rarely used tools and items were assigned a new location and scrap items
were discarded.
The second phase, set in order, resulted in several changes in the organization of the
workplace. Each of the workstations received their own set of tools. All the tools were
color-coded to their respective workstation. All equipment had specific locations.
Trashcans and other items on the floor had floor markers to indicate their locations. All
tools and hoses were removed from the floor and were placed on clamps. Commonly
used parts were placed in bins on every workstation.
The third phase, shine, resulted in removing scrap, dust and other unwanted items
from each workstation. This initial clean-up helped to visualize other issues clearly.
The fourth phase, standardize, resulted in developing SOPs for the employees in the
assembly area. Some of the standards developed were:
Each worker should use the tools assigned to him and put back the tools in their
allocated location after use.
No units should be placed on the floor.
Anytime a tool is missing, it should be immediately reported to the supervisor.
The fifth phase, sustain, resulted in the assembly employees conducting periodic audits
to monitor the changes made through 5S in the assembly area. Once a week, the
activities needed for continuous improvement and the audit results were put up on an
electronic notice board.
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About the authors
Shaman Gupta holds a bachelors degree and masters degree in mechanical engineering from
Kurukshetra University, Kurukshetra, Haryana, India. Presently, he is working as an Assistant
Professor in the Department of Mechanical Engineering at Maharishi Markandeshwar
University, Ambala, Haryana (India). His main research area is lean manufacturing. Shaman
Gupta is the corresponding author and can be contacted at: shamangupta9@gmail.com
Sanjiv Kumar Jain holds a bachelors degree in mechanical engineering from The Institution of
Engineers, Calcutta; a masters degree in industrial engineering from Guru Nanak Dev
Engineering College, Ludhiana; and a PhD from Punjabi University, Patiala, India. Presently, he
is working as an Associate Professor in the Department of Mechanical Engineering at Ambala
College of Engineering & Applied Research, Ambala, Haryana (India). His main research area is
ISO 9000 and lean manufacturing.
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