apparel internship | nift kangra
DESCRIPTION
5s Implimentation | Apparel InternshipTRANSCRIPT
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LEAN MANUFACTURINGIMPLEMENTATION OF 5 ‘S’
Arvind Ltd.Mysore Road
Bangalore
Campus of Arvind Ltd.
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KNITS DIVISION
It has newly been started and has appointed untrained or semi-trained operators.
Eight teams running with 15-16 workstationsOne production cabin and one maintenance and trim issue department. The warehouse of the knits is on the first floor.
Assembly line
Here, an operator finishes her operation; self inspects the quality of work done and then manually passes the panel(s) to the next workstation.
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A SCHEMATIC REPRESENTATION OF A SEWING LINE ON KNITS PRODUCTION FLOOR 0
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Knits Floor : Project Area
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ABOUT 5 ‘S’ 07
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5 ‘S’
SEIRI
SEITON
SEISO SEIKETSU
SHITSUKE
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5 ‘S’
1 ‘S’: SEIRI (SORTING OUT)
2 ‘S’: SEITON (SYSTEMATIC ARRANGEMENT)
Objective
Saving & Recovering SpaceFinding method of Disposal.Finding whose responsibility is to dispose
Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting
What is Involved ?
Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting
Arranging in orderA place for every thing and every useful thing in it’s place.
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5 ‘S’
3 ‘S’: SEISO (SPIC AND SPAN)
4 ‘S’: SEIKETSU (STANDARDIZATION)
Objective
Arranging in orderA place for every thing and every useful thing in it’s place.
Achieving higher productivity and better quality.
What is Involved ?
Clearing the work place / equipmentEnsuring –Tip Top conditionMaking a shine calendar.
Working methodology (procedures and work instructions)Calendars for every activity
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5 ‘S’
5 ‘S’: SHITSUKE (SELF DISCIPLINE)
Objective
Doing it Right first time and every time Sustenance of good practices.Setting of efficient standardsResults should be measureable.
What is Involved ?
Forming the habitTrainingEvery notice board should be updated regularly. Regular evaluation ‘Visual display of standards Increase the transparency levelEasy Induction of New Employee.Clean and Check Standards
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METHODOLOGY Problems Found Evaluation before Implementation Implementation Evaluation After Implementation
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PROBLEMS IDENTIFIED
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Bins not kept at their position and defected pieces lying on
floor unattended
Packaging materials, Unused cartons, carton with rejected
pieces lying on the floor
1 ‘S’ : Sieri• Supervisor’s
cupboard stuffed with sample. elastic, sample threads etc.
• Maintenance utilities jumbled up.
• Tools missing from tool board and drawers
• Incomplete garments lying in cartons on floor without proper information
• Defected garments are lying unattended.
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2 ‘S’ : Seiton
• Violation of Yellow Lines
• No demarcation of places
• No listings of the items in the drawers, difficulty in finding out
• No labeling on Trim Rack, consuming lot of time to find things
No labelling and no listing of items on drawers
Place not defined for the materials
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Dustbin cover open and waste are lying outside the
dustbin
Defect stickers stuck on floor
3 ‘S’ : Sieso
• Grim and Dirt on floor• Defect stickers stuck on
floor everywhere.• No self cleaning done
by operators• Throwing unused or
unattended objects anywhere and not in dustbin.
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WIP on chair
4 ‘S’ : Sieketsu
• No visual guidance for operators.
• No SOP• No single piece movement
(Variable WIP at different workstations)
• Inappropriate uniform of workers
5 ‘S’ : Shitsuke
• Workers not following workplace discipline
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EVALUATION BEFORE IMPLEMENTATION
• Before Implementation.xlsx
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IMPLEMENTATION
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1 ‘S’: SEIRI (SORTING OUT)
SEGREGATE
NEEDED
More Frequently
Keep in middle shelf
Less Frequently
Keep in bottom or top
most shelf
NOT NEEDED
Not Needed At All Discard
Needed But Not Now
Red Tag (With proper
labeling)
Needed But Not Here
Red Tag (With proper
labeling)
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1 ‘S’: SEIRI (SORTING OUT)
STEPS CARRIED OUT
•Sorted out the unwanted things.•The unwanted things discarded. •E.g. unused machine manuals discarded, unused and rejected labels discarded, rejected garments put in carton and put in red tag area, Sample elastics put in a carton, Incomplete garment pieces kept in carton put in red tag area and with proper labeling.
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Red Tag Area
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Name of the object
Area to which the object belongs
Quantity
Authorized Person to handle
Authorized Person to dispose
Used/Unused
Validity
Method of Disposal
Label to be put on every object in Red Tag Area (fields to be filled as required)
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2 ‘S’: SEITON (SYSTEMATIC ARRANGEMENT)
Keyword• Anybody• Immediately
3 Points• Can See• Can Take Out• Can Return
3 Keys• Where? • What?• How much?
STEPS CARRIED OUT• Shelves and drawers arranged• Labeling done ( Position defined )• Poka-Yoke for files• Master Prepared For each Shelf• Layout prepared denoting the position of fans, lights,
exhausts etc and workstations positioning• Layout.xls
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Labeling of fixed positions
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Master Card for Drawers
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Place defined and labelling done
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Labeling done on cupboards and maintenance- tool board
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Labeling done•Racks•Spare Parts of Machine arranged in small cuboids prepared by us and labeled
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•PokaYoke (Error Proofing)
•Master Card for Files
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Output bin as Green color defined and labelled and Input Bin as Blue Colour
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3 ‘S’: SEISO (SPIC AND SPAN)
CLEANING TARGETS
Surroundings Storage Areas Equipments & Machines
Make Calendars
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3 ‘S’: SEISO (SPIC AND SPAN)
Step 1
•Visual Observation of everything
Step 2
•Practically check everything
Step 3
•Take steps for cleansing
•Measure and calibrate
STEPS CARRIED OUT
Shine Calendar prepared
• Floor mopped• Windows Cleaned
• Kept a separate tea stand (Earlier maintenance
department table was used to keep the tea flask)• Racks etc cleaned
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SHINE CALENDAR FOLLOWED
Shine Activity Timing FrequencyResponsible
Person
Workstation
Cleaning
Before starting of
workDaily Operator
Toilets Cleaning 9:00 a.m. & 1:30 p.m. Daily Housekeeping
Sweeping of
Floor9:00 a.m. & 1:30 p.m. Daily Housekeeping
Cleaning of
Office9:00 a.m. Daily Housekeeping
Mopping of Floor Lunch BreakWednesday &
SaturdayHousekeeping
Window Panes Any time of the day Once in a week Housekeeping
Fabric Store/Trim
storeAny time of the day Once in a week Housekeeping
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4 ‘S’: SEIKETSU (STANDARDIZATION)
STEPS CARRIED OUT
•SOP Cards for sewing hung on each workstations•Same color sheet, font face followed everywhere while labeling•Color for input and output bin.•ID card and Uniform ( apron, scarf, mask and gloves in case of white garment) made compulsory.
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SOP Cards hung on each machine for ease of operations
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•All the workers should be thoroughly informed about the recent changes and their benefits•Management Personnel should take care that the rules are followed at all times•Leaders should monitor all the 5S activities continuously.•Create work discipline
5 ‘S’: SHITSUKE (SELF DISCIPLINE/ SUSTAIN) 0
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EVALUATION AFTER IMPLEMENTATION
week 1.xlsx Week 2.xlsx week 3.xlsx
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•Can be adapted by changing the worker mentality•Can be adapted by involvement of the people, awareness of this policy and the huge cost involvement in implementation.•Top management involvement is necessary
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RESULTS AND DISCUSSION
Scores showing execution of 5S on the Knits Floor
Credit wise improvement in all the 5 areas in the execution
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Score Before
ImplementationWeek 1 Week 2 Week 3
28 / 110 39/110 55/110 65/110
Score for each S ( Credit Wise ) Week 1 Week 2 Week 3
1S ( 25 ) 7 11 12
2 S ( 15 ) 11 17 15
3 S ( 25 ) 9 16 18
4 S ( 25 ) 6 5 8
5 S ( 20 ) 6 6 12
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SCORES SHOWING EXECUTION OF 5S ON THE KNITS FLOOR
0
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30
40
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60
70
Before Implemen-tationSeries 1Series 2Series 3
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CREDIT WISE IMPROVEMENT IN ALL THE 5 AREAS IN THE EXECUTION OF 5S
1S
2S
3S4S
5S
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WEEK 1WEEK 2WEEK 3
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CONCLUSION
Reducing the stoppage time of the machine increases the overall quality of product.
Standard procedure eases the working and training requirements for operators
The defective items are reduced.
The floor space is utilised properly.
Material handling time is reduced.
Employee involvement is improved.
Easier and safer work environment is partly achieved.
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THANK YOU
BY:
Bhavya Aditya
Surbhi Karn
B.F.Tech (AP), Sem VIINIFT Kangra
2010-2014
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