Reduction of Scrap and Rework Cost by Implementing 5S …
185
Agrahari et al. [5] implemented 5S methodology in a small-scale industry. From
this implementation, the industry registered major improvements in work efficiency,
the safety of workers and productivity. The study promotes both the workers and
the management to keep this good work ethic alive. Some major advantages after
implementing the 5S method are as follows.
Kumar et al. [6] performed a case study in one of the top industries making
prestressed concrete steel wire, aka PC wires, in India. These wires are primarily
used in bridge construction and road construction industries across the nation. Huge
scrap generation was the prime concern for the industry as it was leading to a lot of
monetary loss. To solve this problem, several total quality management (TQM) tools
were executed. Tools like Pareto chart analysis, Ishikawa diagram (cause and effect
diagram), Kaizen method, etc., were used. The factors causing these stoppages were
found using the above-stated techniques and were solved by taking apt actions.
Rojasra and Qureshi [7] did a case study that focuses on small-scale plastic
industry named Krishna Plastic Company from Amreli, Gujarat, India. The paper
concluded that the 5S method was optimum for reducing clutter around the workplace
by suggesting better places for raw goods or finished goods to put, better workspace
management, less safety endangering incidents, reduction in scrap and rework costs,
better communication between shop floor staff and management staff, tools were not
lost anymore due to proper and better inventory management leading to improved
productivity and efficiency.
Veres et al. [8] did a case study in an Austrian automotive company, Hirchmann
Automotive, based in Mures, Romania. The 5S method was applied in the company,
as a function of the Toyota Production System (TPS). Since its implementation, each
worker of the company was given proper training on how to keep their surrounding
workplace safe and clean and how to work for continuous improvement of the products. As a result of implementing the 5S method, the company noted a drastic increment in not only the quality of the product but also the shop floor was now cleaner.
The safety of the workers increased too, and more importantly, they improved their
efficiency. These results proved that for any industry, the 5S methodology could be
the first step in order to accomplish their progress and goals towards a better future.
2 Case Study
2.1 Company Profile
Om Sai Enterprise is a part of SMEs. It is in Vapi, Gujarat. The company makes special
purpose machineries (SPM) for detergent pharmaceuticals and chemical industries
all over the world at the lowest costs. It has 20 plus years of experience in the
field. Some of the products offered by the company are as follows: all types of
conveyors, sparklite (scrubbing machine), a robotic arm for pick-n-place, tilting
assembly, packaging machines, auto stamper machines, machine spares and SPMs.
185
Agrahari et al. [5] implemented 5S methodology in a small-scale industry. From
this implementation, the industry registered major improvements in work efficiency,
the safety of workers and productivity. The study promotes both the workers and
the management to keep this good work ethic alive. Some major advantages after
implementing the 5S method are as follows.
Kumar et al. [6] performed a case study in one of the top industries making
prestressed concrete steel wire, aka PC wires, in India. These wires are primarily
used in bridge construction and road construction industries across the nation. Huge
scrap generation was the prime concern for the industry as it was leading to a lot of
monetary loss. To solve this problem, several total quality management (TQM) tools
were executed. Tools like Pareto chart analysis, Ishikawa diagram (cause and effect
diagram), Kaizen method, etc., were used. The factors causing these stoppages were
found using the above-stated techniques and were solved by taking apt actions.
Rojasra and Qureshi [7] did a case study that focuses on small-scale plastic
industry named Krishna Plastic Company from Amreli, Gujarat, India. The paper
concluded that the 5S method was optimum for reducing clutter around the workplace
by suggesting better places for raw goods or finished goods to put, better workspace
management, less safety endangering incidents, reduction in scrap and rework costs,
better communication between shop floor staff and management staff, tools were not
lost anymore due to proper and better inventory management leading to improved
productivity and efficiency.
Veres et al. [8] did a case study in an Austrian automotive company, Hirchmann
Automotive, based in Mures, Romania. The 5S method was applied in the company,
as a function of the Toyota Production System (TPS). Since its implementation, each
worker of the company was given proper training on how to keep their surrounding
workplace safe and clean and how to work for continuous improvement of the products. As a result of implementing the 5S method, the company noted a drastic increment in not only the quality of the product but also the shop floor was now cleaner.
The safety of the workers increased too, and more importantly, they improved their
efficiency. These results proved that for any industry, the 5S methodology could be
the first step in order to accomplish their progress and goals towards a better future.
2 Case Study
2.1 Company Profile
Om Sai Enterprise is a part of SMEs. It is in Vapi, Gujarat. The company makes special
purpose machineries (SPM) for detergent pharmaceuticals and chemical industries
all over the world at the lowest costs. It has 20 plus years of experience in the
field. Some of the products offered by the company are as follows: all types of
conveyors, sparklite (scrubbing machine), a robotic arm for pick-n-place, tilting
assembly, packaging machines, auto stamper machines, machine spares and SPMs.