The document summarizes the implementation of the 5S methodology at the knits division of Arvind Ltd. in Bangalore. It describes the 5S principles of sorting, systematic arrangement, spic and span, standardization, and sustaining discipline. Evaluations showed improvements across the 5S areas over 3 weeks. Scores increased from 28/110 before to 65/110 after implementation, indicating better utilization of space, procedures, cleanliness and worker involvement through the 5S process. The conclusion states benefits like reduced material handling time, easier operations and training, fewer defects, and an improved work environment.

1. Campus of Arvind Ltd.
LEAN MANUFACTURING
IMPLEMENTATION OF 5 ‘S’
Arvind Ltd.
Mysore Road
Bangalore

2. KNITS DIVISION
07/12/2013
NIFT Kangra, 2010-2014
It has newly been started and has appointed untrained or semi-trained
operators.
Eight teams running with 15-16 workstations
One production cabin and one maintenance and trim issue department.
The warehouse of the knits is on the first floor.
Assembly line
Here, an operator finishes her operation; self inspects the quality of
work done and then manually passes the panel(s) to the next
workstation.
2

3. A SCHEMATIC REPRESENTATION OF A SEWING LINE
ON KNITS PRODUCTION FLOOR
07/12/2013
NIFT Kangra, 2010-2014
3

4. 07/12/2013
NIFT Kangra, 2010-2014
Knits Floor : Project Area
4

5. ABOUT 5 ‘S’
07/12/2013
SEIRI
5 ‘S’
SEIKETSU
NIFT Kangra, 2010-2014
SHITSUKE
SEITON
SEISO
5

6. 5 ‘S’
What is Involved ?
Segregate
necessary from
unnecessary
Remove what is not
required
Decide on frequency
of sorting
2 ‘S’: SEITON
(SYSTEMATIC
ARRANGEMENT)
Segregate
necessary from
unnecessary
Remove what is not
required
Decide on frequency
of sorting
Arranging in order
A place for every
thing and every
useful thing in it’s
place.
NIFT Kangra, 2010-2014
1 ‘S’: SEIRI
(SORTING OUT)
Saving & Recovering
Space
Finding method of
Disposal.
Finding whose
responsibility is to
dispose
07/12/2013
Objective
6

7. 07/12/2013
3 ‘S’: SEISO (SPIC
AND SPAN)
4 ‘S’: SEIKETSU
(STANDARDIZATI
ON)
Objective
What is Involved ?
Arranging in order
A place for every
thing and every
useful thing in it’s
place.
Clearing the work
place / equipment
Ensuring –Tip Top
condition
Making a shine
calendar.
Achieving higher
productivity and
better quality.
Working
methodology
(procedures and
work instructions)
Calendars for every
activity
NIFT Kangra, 2010-2014
5 ‘S’
7

8. 5 ‘S’
What is Involved ?
Doing it Right first
time and every time
Sustenance of
good practices.
Setting of efficient
standards
Results should be
measureable.
Forming the habit
Training
Every notice board
should be updated
regularly.
Regular evaluation ‘
Visual display of
standards
Increase the
transparency level
Easy Induction of
New Employee.
Clean and Check
Standards
07/12/2013
Objective
NIFT Kangra, 2010-2014
5 ‘S’: SHITSUKE
(SELF
DISCIPLINE)
8

9. METHODOLOGY
07/12/2013
Problems Found
 Evaluation before Implementation
 Implementation
 Evaluation After Implementation

NIFT Kangra, 2010-2014
9

10. 07/12/2013
NIFT Kangra, 2010-2014
PROBLEMS IDENTIFIED
10

11. •
•
•
•
Packaging materials, Unused cartons,
carton with rejected pieces lying on the
floor
NIFT Kangra, 2010-2014
Bins not kept at their position and
defected pieces lying on floor
unattended
07/12/2013
•
1 ‘S’ : Sieri
Supervisor’s cupboard
stuffed with sample.
elastic, sample threads
etc.
Maintenance utilities
jumbled up.
Tools missing from tool
board and drawers
Incomplete garments
lying in cartons on floor
without proper
information
Defected garments are
lying unattended.
11

12. No labelling and no listing of items
on drawers
NIFT Kangra, 2010-2014
Place not defined for the materials
• Violation of Yellow
Lines
• No demarcation of
places
• No listings of the items
in the drawers, difficulty
in finding out
• No labeling on Trim
Rack, consuming lot of
time to find things
07/12/2013
2 ‘S’ : Seiton
12

13. • Grim and Dirt on floor
• Defect stickers stuck on
floor everywhere.
• No self cleaning done by
operators
• Throwing unused or
unattended objects
anywhere and not in
dustbin.
NIFT Kangra, 2010-2014
Dustbin cover open and waste
are lying outside the dustbin
07/12/2013
3 ‘S’ : Sieso
13
Defect stickers stuck on floor

14. 4 ‘S’ : Sieketsu
WIP on chair
NIFT Kangra, 2010-2014
5 ‘S’ : Shitsuke
07/12/2013
• No visual guidance for operators.
• No SOP
• No single piece movement (Variable
WIP at different workstations)
• Inappropriate uniform of workers
• Workers not following workplace
discipline
14

15. EVALUATION BEFORE IMPLEMENTATION
•
Before Implementation.xlsx

16. 07/12/2013
NIFT Kangra, 2010-2014
IMPLEMENTATION
16

17. 1 ‘S’: SEIRI (SORTING OUT)
07/12/2013
Keep in middle
shelf
Less Frequently
Keep in bottom
or top most
shelf
Not Needed At
All
Discard
Needed But Not
Now
Red Tag (With
proper labeling)
Needed But Not
Here
Red Tag (With 17
proper labeling)
NEEDED
SEGREGATE
NOT NEEDED
NIFT Kangra, 2010-2014
More Frequently

18. 1 ‘S’: SEIRI (SORTING OUT)
NIFT Kangra, 2010-2014
•Sorted out the unwanted things.
•The unwanted things discarded.
•E.g. unused machine manuals discarded, unused and rejected
labels discarded, rejected garments put in carton and put in red tag
area, Sample elastics put in a carton, Incomplete garment pieces
kept in carton put in red tag area and with proper labeling.
07/12/2013
STEPS CARRIED OUT
18

19. 07/12/2013
NIFT Kangra, 2010-2014
Red Tag Area
19

20. Name of the object
Authorized Person to
handle
Authorized Person to
dispose
NIFT Kangra, 2010-2014
Quantity
07/12/2013
Area to which the
object belongs
Used/Unused
Validity
Method of Disposal
Label to be put on every object in Red Tag Area (fields to be
filled as required)
20

21. 2 ‘S’: SEITON (SYSTEMATIC
ARRANGEMENT)
Keyword
3 Points
3 Keys
• Anybody
• Immediately
• Can See
• Can Take Out
• Can Return
• Where?
• What?
• How much?
•
•
•
•
•
•
STEPS CARRIED OUT
Shelves and drawers arranged
Labeling done ( Position defined )
Poka-Yoke for files
Master Prepared For each Shelf
Layout prepared denoting the position of fans, lights, exhausts etc
and workstations positioning
Layout.xls

22. 07/12/2013
Labeling of fixed positions
NIFT Kangra, 2010-2014
Master Card for
Drawers
22

23. 07/12/2013
NIFT Kangra, 2010-2014
Place defined and labelling done
23

24. 07/12/2013
NIFT Kangra, 2010-2014
Labeling done on cupboards
and maintenance- tool board
24

25. 07/12/2013
Labeling done
•Racks
•Spare Parts of Machine arranged in small cuboids
prepared by us and labeled
NIFT Kangra, 2010-2014
25

26. 07/12/2013
•Master Card for Files
NIFT Kangra, 2010-2014
•PokaYoke (Error Proofing)
26

27. 07/12/2013
NIFT Kangra, 2010-2014
Output bin as Green color defined and labelled and Input Bin as Blue Colour
27

28. 3 ‘S’: SEISO (SPIC AND SPAN)
CLEANING
TARGETS
Surroundings
Storage Areas
Make Calendars
Equipments &
Machines

29. 3 ‘S’: SEISO (SPIC AND SPAN)
Step 1
Step 2
Step 3
• Visual Observation
of everything
STEPS CARRIED OUT
Shine Calendar prepared
• Practically check
everything
• Take steps for
cleansing
• Measure and
calibrate
•Floor mopped
•Windows Cleaned
•Kept a separate tea stand
(Earlier maintenance department
table was used to keep the tea
flask)
•Racks etc cleaned

30. SHINE CALENDAR FOLLOWED
Shine Activity
Responsible
Timing
Frequency
Before starting of work
Daily
Operator
Toilets Cleaning
9:00 a.m. & 1:30 p.m.
Daily
Housekeeping
Sweeping of Floor
9:00 a.m. & 1:30 p.m.
Daily
Housekeeping
Cleaning of Office
9:00 a.m.
Daily
Housekeeping
Workstation
Cleaning
Wednesday &
Person
Mopping of Floor
Lunch Break
Window Panes
Any time of the day
Once in a week
Housekeeping
Any time of the day
Once in a week
Housekeeping
Fabric Store/Trim
store
Saturday
Housekeeping

31. 4 ‘S’: SEIKETSU (STANDARDIZATION)
STEPS CARRIED OUT
•SOP Cards for sewing hung on each workstations
•Same color sheet, font face followed everywhere while labeling
•Color for input and output bin.
•ID card and Uniform ( apron, scarf, mask and gloves in case of white
garment) made compulsory.

32. 07/12/2013
NIFT Kangra, 2010-2014
SOP Cards hung on each machine for
ease of operations
32

33. 5 ‘S’: SHITSUKE (SELF DISCIPLINE/
SUSTAIN)
07/12/2013
NIFT Kangra, 2010-2014
•All the workers should be thoroughly informed about the
recent changes and their benefits
•Management Personnel should take care that the rules
are followed at all times
•Leaders should monitor all the 5S activities
continuously.
•Create work discipline
33

34. EVALUATION AFTER IMPLEMENTATION

Week 2.xlsx

week 3.xlsx
NIFT Kangra, 2010-2014
week 1.xlsx
07/12/2013

•Can be adapted by changing the worker mentality
•Can be adapted by involvement of the people, awareness of this policy and the
huge cost involvement in implementation.
•Top management involvement is necessary
34

35. RESULTS AND DISCUSSION
Week 1
Implementation
39/110
Week 3
55/110
65/110
Scores showing execution of 5S on the Knits Floor
Score for each S
( Credit Wise )
Week 1
Week 2
Week 3
1S ( 25 )
7
11
12
2 S ( 15 )
11
17
15
3 S ( 25 )
9
16
18
4 S ( 25 )
6
5
8
5 S ( 20 )
6
6
NIFT Kangra, 2010-2014
28 / 110
Week 2
07/12/2013
Score Before
12
Credit wise improvement in all the 5 areas in the execution
35

36. SCORES SHOWING EXECUTION OF 5S ON THE
KNITS FLOOR
07/12/2013
70
50
40
30
20
Before
Implementation
Series 1
NIFT Kangra, 2010-2014
60
Series 2
Series 3
10
0
36

37. CREDIT WISE IMPROVEMENT IN ALL THE 5
AREAS IN THE EXECUTION OF 5S
07/12/2013
1S
15
10
5S
2S
5
0
4S
WEEK 1
WEEK 2
WEEK 3
NIFT Kangra, 2010-2014
20
3S
37

38. CONCLUSION
Material handling time is reduced.
Standard procedure eases the
working and training requirements
for operators
The defective items are reduced.
NIFT Kangra, 2010-2014
Reducing the stoppage time of the
machine increases the overall
quality of product.
07/12/2013
The floor space is utilised properly.
Employee involvement is
improved.
Easier and safer work environment
is partly achieved.
38

39. THANK YOU
07/12/2013
NIFT Kangra, 2010-2014
39
BY:
Bhavya Aditya
Surbhi Karn
B.F.Tech (AP), Sem VII
NIFT Kangra
2010-2014