impact of 5s and kaizen implementation on industrial

International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected]

Volume 10, Issue 5, May 2021 ISSN 2319 - 4847

Volume 10, Issue 5, May 2021 Page 32

ABSTRACT

5S and kaizen are Japanese concepts which are generally used to improve working environment of an organization. This paper high spot the proper implementation guideline required for successful exercise of 5s as a part of the daily management practices. The main pillars of the 5S are- Seiri, Seiton, Seiso, Seiketsu and Shitsuke. These 5S are used doing the all the tasks in proper way and within the time. In the kaizen continuous improvement is occurs as well as use better techniques to simplify the work. The eventual objective of this paper is to increase efficiency and productivity of the organization. Various housekeeping activities are often used first in adopting the continuous improvement way of life. Here adopted some practice at plant are: Sort out what is unneeded; Set-In-Order what must be kept; Shine everything that remains and establish a cleaning schedule; Standardize the system throughout the facility and provide employees with training Sustain the effort with self-discipline and resources and time to improve their workplace.TPM starts with 5S. It is a systematic process of housekeeping to achieve a serene environment in the work place involving the employees with a commitment to sincerely implement and practice housekeeping. Problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Keywords: Kaizen, 5S, Housekeeping, TPM 1. INTRODUCTION 5S is an approach to organize, order, clean, standardize and continuously improve a work area. 5S is not just about housekeeping. The initiative of all the 5S is starts from the letter S so this method known as 5S. The words are Seiri, Seiton, Seiso, Seiketsu and Shitsuke. The meaning of all these 5S are sort out, set in order, cleanliness, standardize and self-discipline. In the 5S councils are also formed to discuss about problems related to productivity and efficiency. Kaizen also play important role in organization. Kaizen increases simplicity of operation by modifies the process consistently [4, 5]. 2. LITERATURE REVIEW A] Rajesh Gautam et al. (2012) discuss the problem which is happened in the industry. This case study discusses about the kaizen implementation in the assembly line in organization which machining front and rear axle. B] Soumya R. Purohit et al. ( 2015) described by using the 5s effectively how the productivity increases at Sphoorti Machine Tools Pvt. Ltd. In this case study he explained all the 5s with its proper use. C] Manjunath Shettar et al. (2015) explained the background of kaizen and also impact of kaizen. He also discusses the techniques which transform the organization in well manner.D] Ravee Phoewhawm et al.(2014) explained a case study of president food management team who supporting kaizen. This team was bestowed by the President Food Company to manage the kaizen events and was requested to meet the seven objectives for continuous improvement. 3. METHODOLOGY Kanban is a data framework that is utilized to control the number of parts to be created in each cycle. The mostregular sorts of Kanban are the withdrawal Kanban, which indicate the amount that the succeeding cycle should pull from the first cycle, and the creation Kanban, which determines the amount to be delivered by the procedure interaction. A provider Kanban is another sort of Kanban that is utilized between the provider and the maker under JIT [4, 6].

Impact of 5S and Kaizen Implementation on Industrial Organisation’s Performance

V.M.Jamadar1, A.D.Awasare2, S.J.Mulani3, S.S.Kanase4, P.S.Gumvant5

1Assistant Professor, Department of Mechanical Engineering, DACOE,Karad (MH), INDIA 2Assistant Professor, Department of Mechanical Engineering, DACOE,Karad (MH), INDIA 3Assistant Professor, Department of Mechanical Engineering, DACOE,Karad (MH), INDIA

4Assistant Professor, Department of Mechanical Engineering, BVCOE,Navi Mumbai (MH), INDIA 5Assistant Professor, Department of Mechanical Engineering, DACOE,Karad (MH), INDIA




5S and kaizen are important techniques which are used to enhance productivity and enhance working environment. We are implementing 5S and kaizen in Summit Industries, Taswade MIDC. This industry is vendor of Emerson Commercial and Residential Solution, Atit. Summit Industry manufactures the cylinder head, valve plate, SM cover and also reworks the valve plate of the hermetically sealed compressor. In the last year they expand their industry but after completing the work they not kept all the equipment in proper way due to this the performance level get affected. So they need 5S and kaizen implementation [5, 7].

A] Seiri – Sort out:

In this industry the rejection area is not a proper way due to this rejection is not easily calculate the rejection which is occurred in the industry. Due to this reason their productivity gets affected. In this industry there are three rejections which are foundry rejection, machining rejection, supplier rejection. We separated all these rejection and place it in proper way.

The benefit of implementing the Seiri is easy identification of the rejected component.

a)Before b)After

Photo 1.Rejection Area

B] Seiton – Set in order Before implementing the Seiton all the tools are not in proper way. When operator needs tools they do not find the tool at that time. But after implementing the Seiton all the tools are in proper way. Also when any third person comes in the industry it should see pleasant. We separate all the tools with their sizes and create the section for example for the spanner, round spanner, hammer, hacksaw, various types of grippers, Allen keys.

a) Before b) After

Photo 2.Tool Board



Volume 10, Issue 5, May 2021 4

a)Before b) After

Photo 3. Bay Marking

C] Seiso – shine :

In the seiso organisation should kept workplace clean it. It should need to kept machine, tools and working envoirnment clean. In the Summit Industry workplace was not clean and the euipment which are needed for machining . Because of uncleaniness and improper arrangement of equipment the environment of industry is not pleasant. Also in the Seiso we have done the bay marking. D] Seiketsu – standardize: Seiketsu describe about keeping good sanitary conditions in an organization. Also the information cleanliness is present i.e. information and communication are clear, easy to read and understand. For improving the working environment and morale of worker we have done awareness session on 5S and Kaizen. In this session we describe the importance of 5S and Kaizen.

E] Shitsuke – sustain In the shitsuke organization should ensure that it should follow the 5S principles in their workplace. Managers should prompt the employees of the 5S principles, and strengthen them through consistent messages and improve performance.. To implement this: • Awareness - All need to understand what 5S is about • Structure - A Structure has to be formulated on how and when 5S activities will be done • 5S Posters

4. KAIZEN IMPLEMENTATION

The Kaizen philosophy has been implemented in organizations around the world as a way to improve production values while also improving employee morale and safety. The Kaizen philosophy may be applied to any workplace scenario due to its simple nature.

A] Fixture improvement:

a) Before b) After

Photo 4. Fixture improvement




In the old fixture only one job is drilled at a time and on the work piece three operations are performed. For completing the all operations time required is high which also affects the productivity.In the new fixture it designed in such a way that all the operations are performed on one fixture i.e. drilling, tapping, 3 drilling and chamfering is done on one fixture. So time required to complete all operation is less than old fixture. Old fixture Time required for operation on SM cover 1. Drilling = 3 minutes

2. Tapping = 20 seconds

3. Drill = 1 minutes

4. Chamfering =20 seconds

Total time required is 4 minutes 40 seconds for one SM cover New Design Fixture: Total time required is 2 minutes for one SM cover To calculate productivity considering 500 jobs per day in two shifts Productivity: By using old fixture 110 jobs per shift then in two shift 220 jobs are manufactured Productivity is 220/500*100 = 41 % By using new fixture 225 jobs per shift then in two shift 450 jobs are manufactured Productivity is 450/500*100 = 90 % B] Idle time reduction:

Photo 5. Outer Facing




Photo 6. Inner Facing

For completing outer facing time required is 3 minutes and to completing inner facing time required is 5 minutes. For completing 100 jobs time required for outer facing is 150.minutes. For completing 100 jobs time required for inner facing is 250 minutes. So the idle time between these two operations is 100 minutes. So to utilize this time we use the fixture which already used in the outer facing.

C] Ultrasonic Washing-

In the Summit Industry the maximum rejection occurs due to oil and solid residue remain in the component. They use traditional washing method by means using water and brush. This method not properly removes the residue. For avoiding this problem we have implemented ultrasonic washing system. Its uses high-frequency, high-intensity sound waves in a liquid to make easy or enhance the elimination of foreign contaminants from surfaces submerge in an ultrasonically activated liquid.

Photo 7. Ultrasonic Washing Machine

5. CONCLUSION The implementation of 5S and Kaizen visible results are achieved such as; idle time reduced, positive changes in Productivity, major change in working environment, increase in moral of workers, proper utilization of available resources. Lean Manufacturing as west reduction tool is particularly suitable for any type of industries was that do not have ERP systems. These comparisons results provide information about the importance of physical flow aspects of manufacturing industries.

6. FUTURE SCOPE

The integration of the entire department will be possible to get maximum output results.

ACKNOWLEDGEMENTS We would like to thank Summit Industries, Taswade MIDC, Karad for giving us this valuable and memorable experience. We acknowledge with thanks to Managing Director , Staff and workers of the Summit Industry . We would like to thank the AGTI’S Dr,Daulatrao Aher College of Engineering Karad.




REFERENCES [1] Rajesh Gautam, Sushil Kumar “Kaizen Implementation in an Industry in India: A Case Study” Dept. of DCRUST,

Murthal Sonepat, Haryana, India April 2012.

[2] Ravee Phoewhawm “A Case Study on Kaizen as a Learning Tool for a Management Team” Rajamangala University of Technology Lanna, May 2014.

[3] Soumya R. Purohit “International Journal of Scientific & Engineering Research”, Volume 6, Issue 8, August-2015.

[4] Manjunath Shettar, Nikhil R, Vithal Rao Chauhan “KAIZEN – A case study” Asst. Professor, Department of Mechanical & Manufacturing Engineering, Manipal, Karnataka, India, May 2015.

[5] M.V.Kavade, Anant Awasare“A Review of Assembly Line Changes for Lean Manufacturing” IOSR Journal of Mechanical and Civil Engineering, (IOSR-JMCE) ISSN: 2278-1684, PP: 01-05

[6] M.V.Kavade, Anant Awasare“Compressor Assembly Line Changes for Integration with Application of Lean Manufacturing Tool”, International Journal ofAdvanced Engineering Research and Studies, Vol. IV/ Issue II/April-June, 2013/E-ISSN 0976-3945

[7] Anant Awasare “Reduction of Waste by Applying Lean Manufacturing Tool for Assembly Line”,International Journal of Engineering Technology, Management and Applied Sciences, February 2016, Volume 4, Issue 2, ISSN 2349-4476,PP: 84-89.

ABOUT THE AUTHOR

V.M.Jamadar has received the B.E. and M.E. degrees in Mechanical Engineering. Currently he is working as Assistant Professor in Dr Daulatrao Aher College of Engineering Karad Dist- Satara State- Maharashtra India. He is having more than 11 years of experience in the teaching field and 2 years of experience in the Industry.

A.D.Awasare has received the B.E. and M.Tech degrees in Mechanical Engineering. Currently he is working as Assistant Professor in Dr Daulatrao Aher College of Engineering Karad Dist- Satara State- Maharashtra India. He is having more than 07 years of experience in the teaching field and 2years of experience in the Industry. S.J.Mulani has received the B.E. and M.E. degrees in Mechanical Engineering. Currently he is working as Assistant Professor and Head of Mechanical Engineering at Dr Daulatrao Aher College of Engineering Karad Dist- Satara State- Maharashtra India. He is having more than 10 years of experience in the teaching field and 7years of experience in the Industry.

S.S.Kanase has received the B.E. and M.Tech degrees in the Production and CAD CAM Engineering respectively. Currently he is working as Assistant Professor in Bharati Vidyapeeth Pune, State- Maharashtra India. He is having more than 10 years of experience in the teaching field . P.S.Gunvant has received the B.E. and M.E. degrees in Mechanical Engineering. Currently he is working as Assistant Professor in Dr Daulatrao Aher College of Engineering Karad Dist- Satara State- Maharashtra India. He is having more than 09 years of experience in the teaching field and 3 years of experience in the Industry.

impact of 5s and kaizen implementation on industrial

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