5s case study pdf

How to Improve Manufacturing Process Implementing 5S Practices: A Case Study

• Conference paper
• First Online: 22 January 2020
• pp 1225–1232
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• Beata Mrugalska 19 ,
• Monika Konieczna 19 &
• Magdalena K. Wyrwicka 19  

Part of the book series: Advances in Intelligent Systems and Computing ((AISC,volume 1131))

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• International Conference on Intelligent Human Systems Integration

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This paper presents the practical implementation of 5S method, which is used to improve the quality and safety in organization. 5S, which comes from the Japanese words (translated in English: sort, set, shine, standardize and sustain), is a practice based on Lean Management system which brings many advantages to the organizations and employees. The practice shows that the activities of 5S methods can be effectively and easily implemented to industry. The main aim of this paper is to describe the implementation of 5S method at a chosen workplace and present its positive impact on quality, safety and ergonomic improvement.

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Faculty of Engineering Management, Poznan University of Technology, ul. Strzelecka 11, 60-965, Poznan, Poland

Beata Mrugalska, Monika Konieczna & Magdalena K. Wyrwicka

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Institute for Advanced Systems Engineering, University of Central Florida, Orlando, FL, USA

Tareq Ahram

University of Central Florida, Orlando, FL, USA

Waldemar Karwowski

Dipartimento Di Ingegneria, Edificio 25, Università di Modena e Reggio Emilia, Modena, Modena, Italy

Alberto Vergnano

Department of Mechanical and Civil Engineering, University of Modena, Modena, Modena, Italy

Francesco Leali

GRESPI, Université de Reims Champagne-Ardenne, Reims Cedex 2, France

Redha Taiar

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Mrugalska, B., Konieczna, M., Wyrwicka, M.K. (2020). How to Improve Manufacturing Process Implementing 5S Practices: A Case Study. In: Ahram, T., Karwowski, W., Vergnano, A., Leali, F., Taiar, R. (eds) Intelligent Human Systems Integration 2020. IHSI 2020. Advances in Intelligent Systems and Computing, vol 1131. Springer, Cham. https://doi.org/10.1007/978-3-030-39512-4_187

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DOI : https://doi.org/10.1007/978-3-030-39512-4_187

Published : 22 January 2020

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A Case Study: 5s Implementation in Ceramics Manufacturing Company

The research work carried out to apply the 5S methodology of lean manufacturing to solve the problems of a ceramic industry in India with the aim to increase the efficiency of all processes and elimination of losses in the company. The objectives of the paper is to reduce the process wastes, smooth the process flow and maintain proper quality control, improve storage facilities, safety, security and process cost savings in a company through case study. Before and after picture are taken for the applying 5S methodology in a company. 5S implemented has been carried out in storage department and insulator department. After implementing of 5S in the storage department the space saving is 12.91% and also certain process wastes are reduced. In insulator department the workplace became efficient and effectiveness

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Please note you do not have access to teaching notes, a case study concerning the 5s lean technique in a scientific equipment manufacturing company.

Grey Systems: Theory and Application

ISSN : 2043-9377

Article publication date: 17 April 2020

Issue publication date: 18 June 2020

This paper's purpose is to help a scientific equipment company make use of the 5S tool on the shop floor so that the organization can become progressively beneficial and increasingly productive.

Design/methodology/approach

The organization has adopted a simple approach for making a suitable team for 5S tool implementation at the workplace. After that, they have used three types of data-collection methods so that these methods could help in the correct introduction of the 5S tool in the business workplace. They have also analysed the regression analysis with the genetic algorithm for the audit scores to predict the behaviour of 5S implementation in the coming weeks.

In this case study, it has been found after the suitable analysis that the 5S tool implementation has resulted in the overall benefits of the workplace. The major benefit achieved with the 5S tool is that the searching time for the tool in the workplace has been improved significantly. Also, the safety level is increased. The 5S audit has been carried out in the workplace and the audit score has been improved from the level of 6 scores (in week 1) to 72 score (in week 24).

Practical implications

5S tool has emerged as an incredible asset and it tends to be actualized in any of the ventures whether it is of a miniature, small, medium or large scale industry. The 5S tool can be applied horizontally at a large scale and it can be applied to almost all the workstations in the workplace.

Originality/value

The presented productions and contextual investigation for the 5S tool will be helpful and useful for all the analysts, experts and all other people who are worried about this subject of the 5S tool and its implementation in the organization.

• Practical applications of grey models
• Lean manufacturing

Gupta, S. and Chandna, P. (2020), "A case study concerning the 5S lean technique in a scientific equipment manufacturing company", Grey Systems: Theory and Application , Vol. 10 No. 3, pp. 339-357. https://doi.org/10.1108/GS-01-2020-0004

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Copyright © 2020, Emerald Publishing Limited

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