Case study: Implementation of 5S results at ceramic kilns (Part 2)

After the completion of S1 and S2, India’s high-tech ceramic kiln has started to clean up the workshop of the warehouse area and the insulating porcelain production area. This is also the last step in the three basic steps to build a 5S culture for organizations.

C. Cleanliness: To maintain a clean and organized work environment, toiletries are used. Many areas of the workshop have problems with hygiene, sometimes from not finding sanitary equipment. So by creating tables for toiletries and where they are right, everyone can know where to get them when needed and where to store them after use. Maintaining this habit is extremely important and this awareness is created by associating hygiene habits with specific workplace responsibilities. In addition, the trash bin is arranged in a convenient location for easy use.

Figure 4: Sanitary ware table

D. Care: After implementing the three items above, the department’s workers have agreed that everyone should contribute to daily workplace cleaning. Furthermore at the end of the week, a master cleaning was carried out. This total cleaning is controlled by a dedicated staff.

E. Ready: After the options are implemented successfully, sustainability is the most important issue. The readiness, preparation, methods, support from employees and managers as well as the ability to adapt to 5S are essential for development. To achieve that, an evaluation board is prepared for the 5S implementation. These reviews are done on a monthly basis and the results are analyzed.

The GEMBA table is used to evaluate all performance parameters, namely safety, productivity, quality, absence of workers, and machine operation. It is an intuitive method for monitoring all day-to-day plant operations and has the ability to provide the cause and response when performance parameters are not being met. In addition, the skills of each employee are also shown on the chart.

The results after 5S implementation are shown:

Warehouse: Many materials, tools, machine components are controlled according to data list. Include size / weight, number of uses per month, location. Based on the frequency of use, materials can be divided into 3 groups: using a lot, using little and not used in a long time. After best sorting, saving area is 12.91%.

Insulating porcelain parts: The productivity of the part is increased, offering solutions to save time in production using human.

Through the implementation of 5S at two workshops of a Ceramics factory, it can be seen that the 5S tool brings many benefits to the business as well as benefits for the employees.

Productivity and Quality Office