190
G. Vora et al.
3 Procedure
Initially, an inspection of their shop floor was done. During the inspection, the Gemba
Walk method was applied to note various observations of any malpractice which
could be happening on the shop floor. Based on these observations, multiple discussions were held with several members of the management side as well as engineers
and workers from the shop floor. Keeping their discussions and suggestions in mind,
an action plan was made with keeping the 5S methodology at the centre of focus.
This action plan included all the possible solutions for the problems discovered at
the company. Furthermore, this action plan also focuses on the management aspect
of the company and has instructions on how to improve the management side of the
company as well.
4 Findings and Discussions
4.1 Findings
During the observation period at the company, various problems were identified and
noted down. After discussing it with the company members and taking suggestions
from them about some major bottlenecks of the company, brainstorming was done
in order to find solutions based on the 5S methodology.
It was found that the company’s major areas of concern are tools and inventory
management, scrap identification and management, rusting of raw materials, lack of
proper storage systems, delay in project completion, etc.
4.2 Discussions
After discussing and understanding the problems thoroughly, an action plan was
made. This action plan contained solutions to these problems. The action plan focuses
on all the problems of the company. It gives suggestions not only for production
processes but for many general issues as well.
To solve the issue of damage to the raw materials and finished goods, a proper
storage system and a dedicated storage area need to be developed at the company
that keeps them separated from each other, unlike the current situation (Fig. 7).
To solve the problem of lost tools and time wasted on finding the right tool and
equipment, there is a dire need of establishing a tool inventory system (Fig. 8).
To prevent rusting and corrosion on the raw materials, the company needs to store
them in a way such that metal-to-metal contact is avoided. This can be easily achieved
by plastic wrapping around the raw materials (Fig. 9).
G. Vora et al.
3 Procedure
Initially, an inspection of their shop floor was done. During the inspection, the Gemba
Walk method was applied to note various observations of any malpractice which
could be happening on the shop floor. Based on these observations, multiple discussions were held with several members of the management side as well as engineers
and workers from the shop floor. Keeping their discussions and suggestions in mind,
an action plan was made with keeping the 5S methodology at the centre of focus.
This action plan included all the possible solutions for the problems discovered at
the company. Furthermore, this action plan also focuses on the management aspect
of the company and has instructions on how to improve the management side of the
company as well.
4 Findings and Discussions
4.1 Findings
During the observation period at the company, various problems were identified and
noted down. After discussing it with the company members and taking suggestions
from them about some major bottlenecks of the company, brainstorming was done
in order to find solutions based on the 5S methodology.
It was found that the company’s major areas of concern are tools and inventory
management, scrap identification and management, rusting of raw materials, lack of
proper storage systems, delay in project completion, etc.
4.2 Discussions
After discussing and understanding the problems thoroughly, an action plan was
made. This action plan contained solutions to these problems. The action plan focuses
on all the problems of the company. It gives suggestions not only for production
processes but for many general issues as well.
To solve the issue of damage to the raw materials and finished goods, a proper
storage system and a dedicated storage area need to be developed at the company
that keeps them separated from each other, unlike the current situation (Fig. 7).
To solve the problem of lost tools and time wasted on finding the right tool and
equipment, there is a dire need of establishing a tool inventory system (Fig. 8).
To prevent rusting and corrosion on the raw materials, the company needs to store
them in a way such that metal-to-metal contact is avoided. This can be easily achieved
by plastic wrapping around the raw materials (Fig. 9).