Creating 5S climate at the shopfloor

Lean manufacturing involves a variety of principles and techniques, all of which have the same ultimate goal: to eliminate waste and non-value added activities at every production or service process in order to bring the most satisfaction to the customer. Lean manufacturing is a systematic approach in order to identify and eliminate waste (non value-added activities). For companies to successfully implement lean; it is very much required that they maintain a proper 5S condition in the whole organization. The "5S" is the vital requirement to make all operations standard whereas it helps to point out the continuous improvement areas. 5S is a simple tool for organizing workplace in a clean, efficient and safe manner to enhance productivity, visual management and to ensure the introduction of standardized working. [1] This study presents an approach for adapting 5S techniques in a production facility and gives a complete guide about a systematic method. Due to increased demand, high product variety, and a push production system, the plant has suffered from excessive wastes, unorganized workstations, and unhealthy work environment. This has translated into increased production cost, frequent delays, and low workers morale. Under such conditions, it has become difficult to implement effective continuous improvement studies. 5S is utilized for achieving project objectives. The work was a combination of both culture changes and physical changes on the shop floor. The project has drastically changed the plant and developed the infrastructure for a successful implementation of lean manufacturing studies.