ETL DEPARTMENT

5S
TEAM
WELCOMES
YOU ALL

Coming together is beginning;

keeping together is
progress;

working together is
success.
2

ETL 5S
TEAM
A USHA RANI
Sr. Technician
(LEADER)
M V SRINIVASU
Foreman
(MEMBER)

P SURYA NARAYANA
Foreman
(MEMBER)

Say YES
to 5S
K HARI
Chargeman
(MEMBER)

P GANGA RAJU
Dy. Technician
(MEMBER)
3

ETL DEPARTMENT PROVIDES SERVICE SUPPORT

TO SHOP ELECTRICAL OF ALL PRODUCTION
UNITS IN THE FIELD OF POWER ELECTRONIC
4
EQUIPMENTS

ETL
DEPARTMENT
PROVIDES
SERVICE
SUPPORT
TO SHOP
ELECTRICAL
OF ALL
PRODUCTION
UNITS
IN THE
FIELD OF
POWER
ELECTRONIC
EQUIPMENTS

AROUND
1200
THYRISTO
R
CONTROL
DRIVES.
AROUND
300 PLCs.

AROUND
30 CNCs.

Systems maintained by ETL Department

DRIVES
Siemens
AEG
NGEF
ANSALDO
ABB
SQUARE-D
CGEE-ALSTOM
BHEL
Russian
systems
Yaskawa

PLC
Siemens
Allen Bradley
GE Fanuc
Telemechaniqu
e
Honey Well
Schneider
ABB
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Systems maintained by ETL

UPS
Siemens
Power One
DB
Vistar
Emerson
HIREL
APLAB
Numeric

CNC
Siemens
Lynx
Burney
ESAB

Working area - Responsibilities

Procures and Maintains the
Electronic PCB spares for
all these systems

Maintains Electronic
Laboratories for repair of
Printed Circuit Boards.

ELECTRO TECHNICAL LABORATORY

OUTLINES

5S MANUAL

5S STEERING COMMITTEE

5S ZONES

ORGANIZATION STRUCTURE

5S AWARENESS ACTIVITIES

5S AUDIT & MONITORING

5S SUSTENANCE

PROMOTIONAL ACTIVITIES

SPECIAL INITIATIVES

MILESTONES

BENEFITS OF 5S

5S MANUAL

OBJECTIVE
To define, document and communicate the
roles, responsibility and authority in order
to facilitate effective implementation of
5S - the work place management system.

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STEERING COMMITTEE
CHAIRMAN:

HOD

CONVENER:

DEPARTMENT 5S COORDINATOR

MEMBERS:

ALL ZONAL COORDINATORS

11

5S ZONES
ETL OFFICE
ETL STORES
ETL LABORATORIES

12

5S DEPARTMENTAL ORGANISATION STRUCTURE

5S Zonal
Co-ordinators

13

5S ???

14

1S-SEIRI

SORTING

15

STEPS TO 1S:
Segregate Wanted & Un-Wanted things .
Remove Un-Wanted ones.
Benefits:
Space Saving & Improvement in Work
Efficiency

16

SEIRI AT LAB:
Before 1S
Wanted & Unwanted material was
at same area

WANTED ITEMS: At MAIN LAB

REDTAG PHOTO

AT MAIN LABORATORY

17

FLOW CHART FOLLOWED FOR RED TAG ITEMS

Segregation of
unwanted/unidentified items
Attach red tag
Move to red tag area
Register
Review as per norm

E WASTE

No

Decided to
Relocate
Yes

Move to designated place

18

LISTING OF E-WASTE

EWASTE
DISPOSAL

19

STORAGE POLICY:
PRIORITY

FREQUENCY OF
USE

HOW TO USE

HIGH

ONCE PER DAY

LOCATE AT THE
WORK PLACE

AVERAGE

ONCE PER WEEK

STORE TOGETHER
NEAR TO WORK
PLACE

ONCE PER MONTH

LOW

ONCE PER YEAR

STORE AWAY FROM

THE WORK PLACE

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SCRAP DISPOSAL
FREQUENCY
1. Dust Bins (organic)

Every day
2. Dust Bins (in-organic)

Twice in a week
3. Disposal of Hazardous

scrap yearly
4. Solid electronic waste

once in a year
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2S SEITON- SYSTEMATIC ARRANGEMENT

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STEPS TO 2S
Decide the Place & Arranging in order.
A place for every thing and every

thing in its place.

Benefits:
Search Time reduced.

23

IMPROVEMENT IN SYSTEMATIC ARRANGEMENT

Numbering of switches done according to their corresponding appliances:

BEFORE 2 S

AFTER 2 S

24

SEITON AT LAB:
Before 2S
ALL THE PROBES WERE MIXED

PROBES ARE PLACED ACCORDING TO

TYPE AND COLOUR

25

IMPROVEMENT IN SYSTEMATIC ARRANGEMENT

2S IN OFFICE

BEFORE 2S

AFTER 2S

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2S AT
BEFORE 5S

LAB:PEEP

AFTER 5S

Place for everything, Everything in its place.

27

2S IN STORES

28

2S in Stores
Before

After

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Inventory Management System

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3S-SEISO:

CLEANING WITH INSPECTION

CLEANLINESS IS NEXT TO GODLINESS

31

STEPS TO 3S ????
Dust Free Equipment / Work Place.
Make it easy to Clean.
Make it easy to Inspect Abnormalities.

Benefits:
Healthy Work environment
Abnormalities are Visible & Corrected.

32

3S AT LAB:

22.02.15

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CLEANING & INSPECTION AT OFFICE:

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4S-SEIKETSU

STANDARDISATION

35

STEPS TO 4S
Standard Procedure for all activities.
Review of Procedures and Work

Instructions at a Fixed Interval.

Benefits:
Achieving Higher Productivity and
Better Quality.

36

ARRANGEMENT AT LAB

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MAINTAINING 5S SCORE BOARDS

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5S LAYOUTS AT AREA SHOP OFFICE AND

LAB

39

STANDARD PRACTICES

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5S-SHITSUKE

SUSTENANCE &
SELF DISCIPLINE

41

STEPS TO 5S
Actions to be taken:
Forming the Habit / Culture.
Regular Training & Update.
Follow the decided things.
Benefits:
Habit of doing it Right First Time and Every
Time .
Total Employees Involvement.
42

AWARENESS TRAINING AT ETL

DEPARTMENT

43

BY CONDUCTING 5S AWARENESS CLASSES

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Posters and Slogans by Prize Winners

45

SYSTEM AUDIT & MONITORING

46

BY CONDUCTING SELFAUDIT:
Before:

Before:

Periodicity: 5 minutes every day

After:

After:

47

BY CONDUCTING MONTHLY AUDIT

INSPECTION
BY
STEERING
COMMITTEE

48

5S SUSTENANCE AT ETL
DEPARTMENT

49

5S REGISTER AND 5S CERTIFICATE

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MAINTAINING 5S CORNER

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5S AT SURROUNDING
AREA

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5S AT GARDENS
BEFORE 5S

14.04.07

04.04.14

ETL AAHLADHAVANAM : THE GREEN INITIATIVE

53

5S AT GARDENS
AFTER 5S

04.04.14

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SWACHH BHARAT ACTIVITIES IN

ETL

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PROMOTIONAL ACTIVITIES

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INTER ZONAL COMPETITIONS HELD AT

ETL DEPARTMENT
Inter zonal competitions were conducted among the zones of ETL:

57

PRIZE WINNING 5S SLOGANS :

58

WINNERS OF 5S COMPETITIONS

59

MILESTONES OF 5S:
Improvements through Kaizens

2017
2016
2015
2014
2005
steering
Re-certification

Certification

Committee
formed

60

KAIZENS AT ETL DEPT.:

LITTLE BY LITTLE, A LITTLE BECOMES A LOT!!

61

KAIZEN 1
TITLE : Easy simulation of Russian PCBs by making test jig
Problem:

Russian PCBs
Male edge
connector is having densely populated
and congested pins which causes short
circuit of connected wires and damage to
the PCB.

Solution:

FEMALE EDGE CONNECTOR

WITH APPROPRIATE WIRING WHICH GIVES
EASY ACCESS FOR SIMULATING THE CARD

Implemented by : Smt Jyothi & team

Benefits:
AVERAGE MAN HOURS REDUCED FOR CARD

REPAIR : 10DAYS
NO DAMAGE TO THE PCB

62

KAIZEN 2

TITLE : To improve the work-place environment at

simadyne test-jig

Problem: More strain on eyes and poor

quality of PCB repair due to poor
illumination

Solution: Test jig is provided with tube light

along with fixture

Implemented by

: Smt Jyothi &

team

Benefits:
Quality of card repair is improved
No strain on eyes

63

KAIZEN 3

TITLE : Preparation Of Ge Fanuc Versamax Plc Test

Jig For Easy Simulation

Problem: Repetitive repair of Power

supply PCBs of GeFanuc Versamax
as there is no Test jig
Solution: TO DEVELOP A TEST JIG FOR
GE FANUC VERSAMAX PLC CARDS

Implemented by

: Smt Jyothi &

team

Benefits:
No quality complaints
Easy simulation of PCBs

64

KAIZEN 4

New format with

data

TITLE : To Ensure 100% availability of Electronic

spares

SPARES REQUIREMENT FORMAT

Problem: The status of spares position was not captured accurately in the format.
QUANTITY
IN NUMBERS
Solution:
The Requirement Record
format did not have
proper
columns for
SL
EQUIP EQUIPMENT
TYPE EQUIVA DESCRI
TOTAL REMARKS
ZONE
MAKE MODEL
NO
MENT CATEGORY
NUMBER LENTS PTION INSTA SHOP ETL REQ. PIPE APPRV INSTAL
reflecting zero and critical quantity spares
LLED
(E) STORE
LINE
LED
DRIVE
An improved format was prepared in consultation
with the Zonal In
CONTR

charges.
1

CCD1

EMS
DRIVE

DRIVE

ABB ACS-800

RDCU02
C

OL
BOARD
WITH
EMS
SOFTW
ARE
ARXR
7210
POWER
SUPPLY

15

Implemented by : Smt Sesha Kumari & team

2 ASP PLC
Benefits:

PLC

GE VERSAM IC200
FANUC
AX
PWR 102

PC
The
and it captures
all the
CO&format is self-explanatory,
SCHN
BMXP34
CPU
3

2,3,C
CCP
C4

PLC

EIDER

M340

2020

M340

Identifications of Zero spares is accurate.

1
0

vital points.
1

262

19

Time taken for preparing budget is optimized.

65

KAIZEN 5
TITLE : Refurbishing of ETL notice board
Problem: Difficulty in reading circulars which
are kept in notice board
Solution: Background card board is fixed and
is covered with velvet cloth
Electrical wiring has been done
Tube light holder arrangement fixed

Implemented by : Smt Sesha Kumari & team

Benefits:
Better illumination
Easy to read circulars
Better aesthetics

66

KAIZEN 6

New format with

data

TITLE : Better monitoring of up-time of the PG

kits, programming units and HMIs

EQUIPMENT UP-TIME RECORD

Problem: There was no proper method for calculating equipment up time for
TOTAL
the equipment maintained by Contract.
DAYS

DATE OF
EQUIPME
JOB
DATE OF
THE
EQUIPME
BREAKDO REFERRAL
DATE
NT
ORDER
ITS
EQUIPM
NT
S.NO
WN
TO
OF in MS EXCEL format which REMARKS
Solution:
A
proper
summary
sheet
was
prepared
REFEREN
REFERE
AVAILABI
ENT
AVAILABI
DATE/TIME MAITENANCE
REPAIR
CE availability of the equipment
NCE
LITY
NOT
LITY
shows the
CONTRACT
AVAILAB
LE
VSP/ETL/M
VSP/ETL/
05/07/2014;
05/07/2014;
SMPS FAN
Implemented
by
:
Smt
Sesha
Kumari
&
team 05-07- 05-071 MSM/ECR3
MMSM/E
_
100%
10.00AM
10.00AM
2014
2014
CLEANED
/25
CR3/25
PC MOTHER
Benefits:
VSP/ETL/M
VSP/ETL/
BOARD AND
05/07/2014; 05/07/2014;
05-0705-072 MSM/ECR3
MMSM/E
_
100%
HARD DISK
10.00AM
10.00AM
2014
2014
Monitoring
/44
CR3/44
NOT
is easy
REPAIRABLE
SMPS
Monitoring is accurate
PROBLEM.
VSP/ETL/
VSP/ETL/
(CAPACITOR
Higher uptime
04/09/2014; 04/09/2014; WRM/CS 04-0910-093 WRM/CSR/
5
94.5%
1000MFD 10V
9.10 AM
9.10 AM
R/PG
2014
2014
PG KIT /04
& DIODE IN
KIT /04
5361B715
REPLACED)

67

KAIZEN 7

TITLE : Improving accessibility of Modulepac

PCBs for repair

Problem: No access for checking Modulepac

PCBs
Solution:A fixture for placing PCB is made
ready
Implemented by : Smt Jyothi & team
Benefits:
Enhanced safety of PCB
Efficient handling
No damage to the PCB

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Tangible benefits after doing 5S:

Savings achieved/incurred:
By conducting exhibition of unwanted PCBs to all the sites at store
(AEG PCBs which are obsolete, CNC m/c PCB etc.,)
Rs. 13,00,000
By doing cleaning at surrounding areas(Labor cost)
(56 days * 3hrs per day * 30 man power* wage)
By making gallery in office In-house
(No.of days * Man power required * wage)
Total savings

Rs. 5,04,000
Rs. 8000

18.12 Lakhs

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INTANGIBLE BENEFITS:

Cleaner & safe working Areas

Reduction in wasted time

Reduction in required space

Improved self discipline

Easy access to required items

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RECEIVING RECOGNITION AWARD2015

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Our success depends on

our ability to continue to improve

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ELECTRO
TECHNICAL
LABORATORY
CONTINUAL
IMPROVEMENT
HOUSE
KEEPIN
G
SWACH
H
BHARAT
H

TRAINING

KAIZEN

5S

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74

For Your Attention

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ANY
SUGGESTIONS???

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