International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017
p-ISSN: 2395-0072
www.irjet.net
Implementation of 5S Methodology in a Food & Beverage Industry: A Case Study Sk. Riad Bin Ashraf1, Md. Mynur Rashid2, Dr. A R M Harunur Rashid3 1Graduated
Student, Islamic University of Technology Student, Islamic University of Technology 3Assistant Professor, Dept. of Mechanical& Chemical Engineering, Islamic University of Technology, Dhaka, Bangladesh ---------------------------------------------------------------------***--------------------------------------------------------------------2Graduated
focused on fostering and sustaining high quality housekeeping. 5S is the beginning of a productive life for everyone, and is a principle to productivity improvement. [2]
Abstract – Food and beverage industry in Bangladesh is a
potential sector and growing rapidly since 2000.This industry alone makes up 22% of the total manufacturing production in the country and around 2.45% of country’s total labor force. This sector of Bangladesh is also impacting global market by exporting food and beverage to 90 different countries. Now a day this sector faces challenges to retain its prosperous position due to uprising of new competitors both in the national and international market. So, continuous improvement is required to overcome these challenges. Various lean tools can be used to achieve this improvement. This paper experiments application of 5S approach to a real world production scenario at a food& beverage industry. Initially, the whole system was analyzed and this showed a lot of incongruities in different areas. Improvement proposals were made based on 5S and were implemented over the course of next few months. From the proposed improvement proposal, lots of benefits such as space saving, money saving, increasing productivity, decreasing rejection of components and many more were achieved.
Lean thinking which is the most successful approach to the industrialization of office and service processes, originally discovered by Toyota [3]. In the Sri Lankan health sector 5S has been identified as the entry point to promote the service quality in health care provision [4]. Two major challenges are in front of organizations’ managers due to the increasing competition in the world. Firstly, in this competitive environment, managers have to make the best judgment and choose the best methods to achieve their target and not to lose very finite opportunities. Secondly, lack of knowledge is one of the most important problems of managers about familiarity with a convenient method to successfully improve the performance of the organization [5]. Service providers must refocus on the production of quality services in order to retain customers’ satisfaction and competitive power in the long run [6]. Y. Johana et al. (2014) in their works have shown that 5S methodology can effectively provide a better workplace for the administration staff of a higher learning institution as they feel more comfortable, safe and organized which in the end could assist them to improve the quality of their work. [7] D. S. Uma and A. Kannan (2010) have shown in the implementation of 5S in HRM that the employees of an organization fail to change while the customer demand and the market expectation changes rapidly. [8]
Key Words: 5s, Productivity, Lean Manufacturing. 1. INTRODUCTION The level of competition has enormously increased exclusively in the past two decades due to globalization and innovations in technology. Every company needs to reach or exceed the customer expectations at lowest possible prices to stay in the business arena. Improvements and innovation break-throughs have become a necessity to stay in business rather than just mere tools to improve profitability of a company. Hence, concepts like Six Sigma, Lean Manufacturing, Continuous Improvements, Quality Circles (QCs), Just-in-Time (JIT) are gaining popularity these days. Lean Manufacturing is the hymn of survival and success of any organization through minimizing the waste (Mu-da). One of the basic and the most significant tools to implement Lean Manufacturing is 5S methodology. It is a system to regulate the work flow by systemizing the workplace, thus supporting the culture of continuous improvement [1].
In 2010 a research was conducted on the topic of “Implementation of 5S practices in the manufacturing companies: A case study” (Rahman et al. 2010). The researchers executed 5S rules in two manufacturing companies. 5S checklist was developed for each division for auditing process. Both the companies associated with the research performed an excellent 5S practice. This study proved that 5S is an effective technique in improving housekeeping, health and safety standards in the workplace as well as environmental performance. The study also concluded that effort and participation from top management is a must for proper implementation of 5S. [9] 5S along with some other lean strategies were introduced in a metal structures production system.This resulted in a reduction of lead times, work in progress, transports, deliver
One of the most essential and widely applied components of lean philosophy is the 5S process. Its application is simple and involves basic common sense. 5S is a Japanese tool,
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