5S in Manufacturing

A work place organization method, developed to, create a comfortable working environment, increase productivity and efficiency and reduce waste. It is typically the first lean method, which also provided foundation on which other lean methods – six sigma, cellular manufacturing, just-in-time production, etc. were introduced.

The 5S methodology which originated in Japan, is based on the notion that the foundation of a good production system is a clean and safe work environment. The 5S – Seiri, Seiton, Seiso, Seiketsu and Shitsuke are translated from Japanese language to the closest English equivalents - Sort, Set in order, Shine, Standardize, and Sustain. Apart from the 5S’s, three other S’s are sometimes included – Safety, Security and Satisfaction. 

SORT – (seiri)

Organizing the work area, by keeping only the essential tools and materials to perform the required task, so as to increase the product quality and productivity. Sorting also helps reclaim valuable floor space. “Red tagging” is one effective visual method used for sorting (Red-tagged items are those not important to perform the required task).

SET IN ORDER – (seiton)

Systematically arranging necessary objects to eliminate waste in production and clerical activities. Placards to designate proper storage locations, outlining work areas are few of the strategies for effective set in order.

SHINE – (seiso)

Maintaining clean and well swept work area, which is safer and mess-free. Potential problems caused by any sources of contamination can be easily identified and rectified, by developing standards and norms for cleanliness.

STANDARDIZE – (seiketsu)

Developing and formulizing standard operating procedures for carrying out tasks and procedures. Orderliness is the core of “standardization”. The most widely used tools to standardize the practices are job cycle charts and visual cues.

SUSTAIN – (shitsuke)

It is the one that keeps the first four S’s going and perhaps is the most difficult S to implement. The prerequisites for sustaining the 5S cycle - Imparting the necessary training, encouraging workers to properly maintain and continuously improve operating procedures and the workplace environment.

5S – Its application at a manufacturing company – Toyota

Toyota was the first company to implement 5S and the main objectives to adopt 5S were to facilitate team work, eliminate wastes that contribute to errors, defects and injuries. The company had implemented 5S by imparting the necessary training to the workforce from the shop floor to the management and rewarded to encourage them, to maintain and continuously improve operating procedures.

5S being one of the important principles of Toyota company, helped it achieve high performance that continues to add value to customers.

Though 5S is a system designed to build a work ethic that is practical, efficient and highly disciplined, it has a few potential short comings like increased use of paints and cleaning supplies, increased waste generation leading to complications in waste handling. However, the advantages of 5S far outweigh the disadvantages. 

The article has been contributed by Sujitha Tikka, who is presently a first year PGP student at IIM Raipur. She has worked with Aarvee Associates architects engineers & Consultant Pvt Ltd for 25 months. Her areas of interest include Supply chain management & logistics.She can be reached at pgp12048.sujitha@iimraipur.ac.in.

References

www.lmsi.ca/5s.htm

http://www.clamshellbeachpress.com/html/book1_sample.pdf

The 14 Principles of the Toyota Way: An Executive Summary of the Culture behind TPS

Book Review Competition: The Toyota Way

Among the various exciting events in Equinox ’12, the OPEP club, on 6^th March, organized Critique, a book review competition for the international bestseller “The Toyota Way” authored by Dr. Jeffrey Liker. The participation was overwhelming as students from various reputed B-schools across the country sent their entries soon after the organizers invited them over a month back.

Among the many entries received, the best three were shortlisted and the students were invited to present their book reviews at IIM Raipur Campus in the presence of a judging panel and the students participating in Equinox ‘12. The members of the panel were Prof. O. S. Vaidya, Faculty of Operations & Supply Chain Management, IIM Raipur and Prof. Naval Bajpai, Faculty of Statistics and Business Research, IIM Raipur.

The finalists presented their understanding of and views about the wide and often less understood subject called “Lean Practices”. The basic fundamental ideas presented in the book were discussed at length. The final results of the competition are as follows:

• First Position – Akshay Agarwal, PGP 2011-2013
• Runners up – Harish Verma, PGP 2011-2013 and Mehul Bardia, PGP 2011-2013 (Jointly share runners up position)

The winning entry will be published in the forthcoming edition of Strive magazine. The book review presentations of Harish and Mehul are given below.

Book Review: The Toyota Way by Harish Verma

View more PowerPoint from opepiimraipur

Book Review: The Toyota Way by Mehul Bardia

View more PowerPoint from opepiimraipur

Japan Earthquake: A supply chain catastrophe

Japan suffered from one of the most devastating earthquakes in the nation’s history. The lives lost and damage done to the property is irreparable. We shall take a look at the adverse effect this tragedy has on the global supply chain.

Worries about supply-chain disruptions from Japan's earthquake continue, with some Asian businesses slowing production to preserve stockpiles of crucial components.

But some Japanese factories reported progress in restarting operations, raising hopes that long-term disruptions might be avoided. Japanese-made equipment and materials play a key production role in many of the region's main industries, from automobiles in Thailand to semiconductors in the Philippines. While many businesses said they have adequate inventories of materials for the time being, some were cutting output as they attempted to gauge the impact of the earthquake and disruptions caused by continuing problems at the Fukushima Daiichi nuclear power plant.

In Thailand, Toyota Motor Corp., Thailand's single biggest auto maker is slowing production to preserve stockpiles of Japan-made components, such as the transmission for Camry and Prius hybrid models. "Slowing production now is better than maintaining full output and having a problem later," a Toyota executive said. He declined to say how much production would be reduced.  Other Toyota models face less of a problem because they use a higher percentage of Thailand-made parts. Some 90% of the components used to make Toyota's Thailand-made pick-up trucks are made in the country, compared with 60% for its passenger cars. In Japan, Toyota said it would resume production of replacement auto parts for the domestic and overseas markets soon.

Nissan said it will resume output at two plants in Japan but keep operations at three other vehicle assembly plants in Japan closed until later. Some other factories in Japan have reopened, except for Suzuki and Honda.

Production problems continued in other industries. In a possible blow to global production of consumer gadgets such as smartphones, Mitsubishi said the building and equipment at a plant in Fukushima prefecture had been damaged by the earthquake and that operations were suspended. The plant produces materials for printed wiring boards for use in smartphones and other consumer electronics and makes up to 60% of the global market for wiring-board materials.

The Philippines semiconductor industry association said it was concerned that the disaster in Japan could disrupt the supply of raw materials from the country and affect the export of Philippine-made components back. "A prolonged abnormalcy in Japan will certainly affect the material supplies in the Philippine electronics industry," said Ernie Santiago, president of the Semiconductor and Electronics Industries in the Philippines.

Some of those raw materials include substances such as bismaleimide-triazine, or BT, resin, which is used in making printed circuit boards. Japan provides around 90% of the world's supply of BT resin, Credit Suisse Group AG said.

In some cases, manufacturers will be able to shift to chip suppliers outside Japan. But that can be difficult if product specifications call for a particular brand, said Paul Romano, chief operating officer of Fusion Trade, an Andover, Mass., company that helps manufacturers find sources of scarce components. He said the company has been retained to find components by more than 15 clients. He said they don't allow his firm to disclose their names.

This just shows the side effects of a global supply chain. In a country like Japan, which is home to many high technology industries like automotives and electronics, a natural disaster of this magnitude can cripple supply chains of even major corporations. The indispensable nature of Japanese parts and finished goods will create a ripple effect across many industries for a long time. At a time when the world is just coming back on its feet from the global financial crisis, a production slowdown will further dent the economic recovery shown in the developed nations.

Vishwajit Vyas has done his B.Tech. in Electronics Engineering from Wayne State University, Detroit,  Michigan and can be reached at vishwajitvyas @ gmail . com.