What is the use of 5S in process analysing? Is it helpful to reduce the processing time?

 A. Introduction

Many of us knew that, “The 5S is a tool to organize the work-shop, It is also a tool for process analyzing and improving” This may look like a new concept. The common understanding about the 5S is a tool to organize the workplace. But it is an effective tool for process analyzing and improving. We could apply this concept for a single process or multiple processes to analyze. In end, you could get improvement in the process without any doubts. Because I am experienced to use the tools for cross-functional processes. It is quite an interesting and new dimension of Industrial Engineering for the Process analyzing approach.

 B. Cases study for Better understanding  

We keep on facing a lot of problems on the productions floor. In some processes achieving production with quality is complicated. Subsequently, it is becoming a bottleneck in the production line.

Example:

Process: Scalloping shape Lace attach, Machine: Zig Zag Machine

Before Average cycle time = 130 seconds

After Average cycle time = 55 Seconds (~75 seconds were reduced)

We reduced 60% of timing and production was double with good quality.  

C. Refer to the below video before improvement

D. Refer to the below video after improvement

E. How it is reduced by using the 5S concept

1. Sort: Clearly written the process break up in every second process timeline. Removed the unwanted process.

Examples: a) Eliminated two times pick-up for front and back, The Lace attaching process shifted after closed side seam. b) Removed around 52 unwanted stops at curve shape, trained to do single stop. c) Removed folding and unfolding the garment, So on.       

2. Set in order: Reordered process breakdown with a systematic process.

Examples: a) Body panel moved to left-hand holding and right hand controlling the sewing, b) Ordered machine, leg hand and eye coordination to drive without stopping even at curve shape, c) Brought all tools and panels closed to the needle.   

3. Shine or Sweep: Once redesigned the process, the educated operator clearly about what we going to do and how to do it. Made crystal clear to understand and follow the same.  

Examples: a) Minimum manufacturing requirement, b) Self-checking, c) Self-adjusting based on her won experience, e) Cleared her doubts and motivated to do without any doubt.  

4. Standardize:  All parameters set well and standardized. Example: Machine setting, RPM, Feeding method, Margin allowance, etc.    

5. Sustain: Same is followed continually to sustain

F. Conclusion:

The 5S process analyzing and improvement concept applied to many processes. In the later stage, we promoted to apply that to the entire factory. We got improvement in all aspects. Effective will be there when we use the 5S concept in cleaning or organizing the workplace. We could make it more effective even in process improvement also by using the 5S concept.