RECTIFICATION IN PLANT LAYOUT BY IMPLEMENTATION OF 5S

Transcription

1 International Journal of Scientific Research in Engineering (IJSRE) Vol. (), March, 7 RECTIFICATION IN PLANT LAYOUT BY IMPLEMENTATION OF 5S Abhay Tiwari, Rishabh Dubey Student, Mechanical department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat Corresponding Author Detail: Abhay Tiwari Student, Mechanical department, Laxmi institute of Technology, Sarigam-Valsad, Gujarat. Internal Guide Detail: Mr. Ashish Patel Assistant Professor, Mechanical department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat. ABSTRACT 5S is a basic foundation of Lean manufacturing systems. It is a tool for cleaning, sorting, organizing and providing the necessary groundwork for workplace improvement. This research effort dealt with the implementation of 5S methodology in the Prime Housewares Private limited, Somnathroad, Dhabel, Daman. A detailed application of the 5S system is given. It will impact the instructors and workman of Industry that work within the selected place. By following the 5S methodology, this research effort may show significant improvements to safety, productivity, efficiency, and housekeeping. The research documents improvements by using before and after pictures. It also intends to build a stronger work ethic within the workman and engineer who would be expected to continue the good practices. KEYWORDS: 5S, Workplace Management. INTRODUCTION Plastic moulding is very widely used process in today s world. Due to the high cost of metallic materials and their lack of availability the plastic materials are very widely used in many applications. The plastic material has very good qualities and their qualities can also be improved easily by the use of catalyzers. Thus plastic moulding is getting very high attention. Plastic moulding has very wide classification. Plastic products with simple shapers are easy to manufacture. But products with complex shapes are difficulty to manufacture the injection moulding is used. Injection moulding machines are used for their high productivity and high quality of production. In injection moulding the products which require uniform thickness with high density are easy to manufacture. The plastic moulding industries are replacing their conventional machines by the injection moulding machines due to their high productivity and user friendly control. In Prime Housewares,Private limited by conducting study that helped us to identify the problems with the environments, safety and cleanness of the industry.5s is a system to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results the term refers to five steps sort, set in order, shine, ize, and sustain that are also sometimes known as the 5 pillars of a visual workplace. 5S programs are usually implemented by small teams working together to IJSRE Vol. (), March, 7 Page

2 International Journal of Scientific Research in Engineering (IJSRE) Vol. (), March, 7 get materials closer to operations, right at workers fingertips and organized and labeled to facilitate operations with the smallest amount of wasted time and materials. A place for everything, and everything in its place is the mantra of the 5S method, and storage and workspace systems such maximum use of cubic space for the highest density storage. The result is an improved manufacturing process and the lowest overall cost for goods produced. COMPANY INFORMATION Name of Industry: Prime Housewares limited. Address: 9A, GDDIDC, Somnath, Daman 96. Product produces: Mug Fruit Container Buckets Bowls etc. Process: This is small industry. In which plastic granules is used as raw material and this raw material is converted by injection moulding process into the finish good or different parts. First raw material from the store is taken to manufacturing unit. After it is inspected and then it is send to mixing room where mixing is carried out. After mixing again inspection is done that pigment is properly mixed or not. Then after inspection plastic injection is done with the machine. Then finishing is done. then it is send to packing department where final product is packed. AREA OF STUDY Objective of study: To keep the work place cleans, efficient and safe. Problem identification: While studying, identified problems are:. Tools (moulds) are not properly kept.. Need of cleanliness and tidiness.. Spare parts and materials are present in workplace.. Location for containers, Boxes, Bines, materials is not clearly defined. 5 S STRATEGY 5S is a strategy for attaining workplace organization and cleanliness, and it will improve quality, productivity and moral than any other lean manufacturing improvement. Below fishbone diagram shows various phases of 5 S methodology. In each phase, we have described the problem by using this phases we have solved the work place management problem. IJSRE Vol. (), March, 7 Page

3 International Journal of Scientific Research in Engineering (IJSRE) Vol. (), March, 7 Figure- Fishbone Diagram The first 'S' stand for Seiri (Sort). It is a waste reduction step; all materials are separated as necessary and unnecessary. Sorting lamination of waste materials (raw materials, tools and material) and damaged tools. To sort out necessary and unnecessary materials red tag is used. It s helps to maintain the clean workplace and improves the efficiency of searching and receiving things, shortens the time of running the operation. In sorting we distinguished the useful and scrap items. Figure- Before sorting Figure- After sorting The second S stands for Seiton (Set in order). The materials that were separated in earlier stage is stored orderly and labeled, so as to it will easily found whenever required. It will reduce the time required for searching the materials and tools. Figure- Before Figure-5 After The third S stands for Seiso (shine), It is related to the cleaning, shine and sweeping of workplace and machinery. During cleaning, it is checked the cleanness of machine, workplace area, and sources of light, preventive maintenance of the machinery and equipment etc. IJSRE Vol. (), March, 7 Page 5

4 International Journal of Scientific Research in Engineering (IJSRE) Vol. (), March, 7 The fourth S stands for Seiketsu (ize), In this step procedure, audit sheet and work instructions are prepared to maintain Seiso. Before starting of work to check and correct the sorted items, placing equipment s at its place and cleaning etc, and give proper reading on audit sheetand create awareness in employee to maintain this thing on production line or on nonproductive line. Condition Observed Very Good (perfect condition) Good (- problems) OK (- problems) Bad (5-6 problems) Very Bad (above 7 problems), or non existant (check box) To calculate 5S score PRODUCTION 5S CHECKSHEET 5. This is now your 5S score Date : Number Item. Add up each column. Add each column together to get total. Divide total by 8. Multiply this score by 5 Audited By : Sort (Means removing from the workplace all items that are not needed for current production) Straighten (Can be defined as arranging items so that they are easy to use and labelling them so that they are easy to find and put away) Shine (Means sweeeping floors, wiping off machinery, and generally making sure that everything in the factory stays clean) All fire extinguishers are charged, eye wash stations labelled and first aid equipment available and labelled Area Audited : Standardise (It is the state that exists when the first three S's are being maintained) Sustain (Making a habit of properly maintaining correct procedures) H&S Environmental Are recyclable materials in non-recyclable containers Each area has specified recycling containers All outside surfaces of recycling containers are clean Waste disposal s exist and are displayed Employees in the area are using the containers to Facilities Are facility items in the area broken, damaged Have items in the area been identified that are broken or damaged? The area has floors swept, machinery clean and generally clean Has maintenance request been raised? Does an area have a planned maintenance schedule for all facilities issues? Floors & Gangways Free of obstructions Floor Marked per plant Clean (No Dirt, No Spills, No Oil) Floor marking created and posted in the area Daily checksheet in place with sign off & date with improvement action items Duty Technician Does Duty technician rota & exist Rota is displayed and labelled Is rota board clean / good condition Duty technician exists for the area Duty technician rota is being carried out to No tooling (measuring equipment, torque wrenches, pressure gauges) in area out of calibration tooling, fixtures & jigs Are all tooling s adhered to at all times? Are all hoses, cabling & wires clean, in good condition and blanked (hoses only)? wires, cabling & hoses Are all wires, cabling & hose s adhered to at all times? Are all workbenches & surfaces s adhered to at all times? 5 6 Tooling, Fixtures, Jigs No Tools, fixtures & jigs on workstations unless in use Point of use Items have designated and clearly organized storage location 7 Wires, cabling & Hoses No un-used wiring, & hoses present or trailing Are all Wiring, cabling and hoses organised and identified? Are safety glasses clean and in good condition Area plan identifies eye wash stations, fire extinguishers, and fire exits Are PPE and safety s being adhered to by all employees in the area 8 Workbenches & surfaces No un-necessary items on workbenches or work surfaces Workbenches and work surfaces are organized Workbenches and work surfaces are clean and in good condition Does a exist in the area that describes what the workbenches and surfaces should require 9 Visual tracking boards All information is current and necessary? Department visual tracking board layout constant with plant All postings are neat & orderly in appearance Area exists and is posted to define layout and format Are all visual tracking board s adhered to at all times? Red Tag Are there items requiring red tags within the area Red Tag area is designated and labeled, all items tagged with date placed in area Red tag area to be clean Area plan identifies red tag area Red tag area is maintained to correct procedure Mobile Equipment No un-necessary mobile equipment present Storage locations for mobile equipment are designated and labeled All are free of debris and none are damaged Area plan identifies location mobile equipment Mobile equipment is located in correct area when not in use No material storage areas are overflowing All material storage areas are clearly designated and labeled Material storage areas only contain WIP and/or pre-kitted items material storage Items are returned to designated area when not in use Cleaning s and or cleaning station exist Cleaning s & cleaning station are designated and labelled Cleaning equipment is stored in correct location and in good condition Cleaning s exist and have daily sign off and date Daily cleaning s are adhered to Guards and shields in place where required All machine windows are cleaned regularly to area Machine guards, interlocks have planned maintenance and schedule Machine guards, interlocks are maintained to planned maintenance Storage Cleaning Standards Machine Guards, Windows & All interlocks are operational Interlocks SECTION TOTALS : Are there fire extinguishers, fire exits clear, PPE available, eye wash stations and first aid equipment available GRAND TOTAL C:\Users\mayankdubey\Desktop\project IDP\[5S audits check sheet and comments sheet -issue.xls]5s Checksheet / 8 5S SCORE Figure-6 Production 5S checksheet The fifth S stands for Shitsuke (sustain), Sustain is about the mental and physical disciplines required to maintain the other Seiketsu items. It is done with help of co - operation between employees, store keeper, engineer and manager. RESULTS AND DISCUSSION No. Process Before (min) After(min) Increased Effectiveness (%) Mould searching time (average)...57 Raw material traveling time...8 Mould arrangement Overall change in percentage % Table- Result Time Analysis of Implementation of 5S Time analysis or Time comparison play an important role in a company or industry to improve working and productivity efficiency. Time analysis nothing but comparison of operation time means how much time take by the process, IJSRE Vol. (), March, 7 Page 6

5 International Journal of Scientific Research in Engineering (IJSRE) Vol. (), March, 7 manufacturing of product, searching of tools and materials, etc., We have implement 5S in Filter Leading company, what is effectiveness after implementation of 5S we have recorded and compared it with old record, effectiveness of 5S before and after implementation is given above Table. CONCLUSION The 5S is an effectiveness to manage tools and materials which can improve housekeeping, environmental conditions and health and safety s and increase productivity and quality. 5S sort stage eliminates unused, unwanted material from the storage room which reduces clutter. Set in order allocates space for components, due to this it give more space for storing more material and tools and results in reduction in searching time. 5S reduce the searching time and improve the production and quality of the products and employees and organization become self-disciplined. REFERENCES. Aziz Wan Asri Wan Abdul, Mat Azman Che, The Effectiveness of Implementation of 5S on Employee Motivation,Business and Social Sciences Review (BSSR), Vol., No., pp. -5,.. Osada T. The 5S: Five Keys to a Total Quality Environment, Asian Productivity Organization, Tokyo.99. Nilipour Akbar, Jamshidian Mehdi, 5S As an Environmental Organization Management Tool; Benefits and Barriers, rd International Management Conference, pp.-, 5 IJSRE Vol. (), March, 7 Page 7