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G. Vora et al.
Scrap is waste which either possesses no economic value or only the value of
its original material recoverable through recycling. Scrap is classified as obsolete,
surplus, obsolescence, salvage, reclaimable, hazardous, non-hazardous, metallic,
plastic, etc. Scrap management includes classification of scrap, decisions whether to
send the scrap for recycling or to employ a third-party contractor for its treatment.
Excessive scrap on the other side is generated due to unplanned machining operations. If proper sequencing of every machining operation is done, the scrap can be
reduced.
If a part does not meet the quality standards during the inspection, rework is
needed. The reason may be either human or machine error. The part is further
inspected to whether it can be sent for rework or has to be scrapped. After inspection, detailed errors and parent production processes are identified. Due to this error,
backtracking needs to be done, which increases the time and diminishes quality. High
scrap rates lead to high material costs and lost time making parts that will not bring
any money. By effectively managing rework and scrap, time and money can be saved
while reducing interruptions in production, resulting in a better-quality product.
5S is a method developed by the Japanese industries. It stands for “Seiri (Sort),
Seiton (Set in order), Seiso (Shine), Seiketsu (Standardize) and Shitsuke (Sustain)”
derived from the original Japanese words. 5S aims at organizing the workplace,
which in turn uplifts the staff’s performance [1–4].
Seiri (Sort): It is determined what tools, objects and parts are needed for the manufacturing of the product, and all the objects are divided into two categories, necessary
and unnecessary. All the unnecessary objects that are not needed in the generation
of the product are eliminated from the shop floor, following the idea that everything
that is not used to complete a work process should leave the work area.
Seiton (Set in order): The aim is to smoothen out the processes by decreasing the
time required to complete them. By placing everything in proper order, energy and
time spent to find specific items will be eliminated. When put in use effectively, one
can find the right item at the right time that too very easy; that is the goal of this step.
Seiso (Shine): It promotes cleanliness in the workplace to increase hygiene, which
will make the workplace pleasing. To create a clean worksite without garbage, dirt
and dust, first, it is necessary to identify the problems like leaks and spills that are
the cause of it. It is important to identify the root causes of dirtiness and correct the
process to prevent them.
Seiketsu (Standardize): It means to standardize to set up standards for a neat and
clean workplace. This process directs to develop a set of rules and procedures to
develop a routine. This routine will induce a habit in the workforce to follow the
above three steps. Due to standardization, any malpractice can be easily identified
and taken care of.
Shitsuke (Sustain): The last step is all about maintaining the 5S process
throughout. A self-discipline routine to follow the above steps will show gradual
results. Regular checks or audits of the workplace and staff’s feedback will help
in identifying needed improvements. It is a method of implementing behaviours
and habits to maintain the established standards over the long term and making the
workplace organization the key to managing the process for success.
G. Vora et al.
Scrap is waste which either possesses no economic value or only the value of
its original material recoverable through recycling. Scrap is classified as obsolete,
surplus, obsolescence, salvage, reclaimable, hazardous, non-hazardous, metallic,
plastic, etc. Scrap management includes classification of scrap, decisions whether to
send the scrap for recycling or to employ a third-party contractor for its treatment.
Excessive scrap on the other side is generated due to unplanned machining operations. If proper sequencing of every machining operation is done, the scrap can be
reduced.
If a part does not meet the quality standards during the inspection, rework is
needed. The reason may be either human or machine error. The part is further
inspected to whether it can be sent for rework or has to be scrapped. After inspection, detailed errors and parent production processes are identified. Due to this error,
backtracking needs to be done, which increases the time and diminishes quality. High
scrap rates lead to high material costs and lost time making parts that will not bring
any money. By effectively managing rework and scrap, time and money can be saved
while reducing interruptions in production, resulting in a better-quality product.
5S is a method developed by the Japanese industries. It stands for “Seiri (Sort),
Seiton (Set in order), Seiso (Shine), Seiketsu (Standardize) and Shitsuke (Sustain)”
derived from the original Japanese words. 5S aims at organizing the workplace,
which in turn uplifts the staff’s performance [1–4].
Seiri (Sort): It is determined what tools, objects and parts are needed for the manufacturing of the product, and all the objects are divided into two categories, necessary
and unnecessary. All the unnecessary objects that are not needed in the generation
of the product are eliminated from the shop floor, following the idea that everything
that is not used to complete a work process should leave the work area.
Seiton (Set in order): The aim is to smoothen out the processes by decreasing the
time required to complete them. By placing everything in proper order, energy and
time spent to find specific items will be eliminated. When put in use effectively, one
can find the right item at the right time that too very easy; that is the goal of this step.
Seiso (Shine): It promotes cleanliness in the workplace to increase hygiene, which
will make the workplace pleasing. To create a clean worksite without garbage, dirt
and dust, first, it is necessary to identify the problems like leaks and spills that are
the cause of it. It is important to identify the root causes of dirtiness and correct the
process to prevent them.
Seiketsu (Standardize): It means to standardize to set up standards for a neat and
clean workplace. This process directs to develop a set of rules and procedures to
develop a routine. This routine will induce a habit in the workforce to follow the
above three steps. Due to standardization, any malpractice can be easily identified
and taken care of.
Shitsuke (Sustain): The last step is all about maintaining the 5S process
throughout. A self-discipline routine to follow the above steps will show gradual
results. Regular checks or audits of the workplace and staff’s feedback will help
in identifying needed improvements. It is a method of implementing behaviours
and habits to maintain the established standards over the long term and making the
workplace organization the key to managing the process for success.