Reduction of Scrap and Rework Cost by Implementing 5S …
187
Fig. 1 Scrapped prototype
Fig. 2 Allen key on the shop floor
Another problem that came up during the discussion was of managing the
manpower and machines. Due to random sequencing and scheduling of the work
amongst machines and workers, the lead time increases drastically. In some cases,
it happened that out of four similar machines, only two of them were repeatedly
used, while the rest were idle. The case is the same with manpower; if before assembling, grinding needs to be done, then the workers assigned for assembling wait for
the grinding to complete, which increases their idle time. Another concern for the
187
Fig. 1 Scrapped prototype
Fig. 2 Allen key on the shop floor
Another problem that came up during the discussion was of managing the
manpower and machines. Due to random sequencing and scheduling of the work
amongst machines and workers, the lead time increases drastically. In some cases,
it happened that out of four similar machines, only two of them were repeatedly
used, while the rest were idle. The case is the same with manpower; if before assembling, grinding needs to be done, then the workers assigned for assembling wait for
the grinding to complete, which increases their idle time. Another concern for the