Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 30379
Applying 5S Lean Technology: An Infrastructure for Continuous Process Improvement

Authors: Raid A. Al-Aomar

Abstract:

This paper presents an application of 5S lean technology to a production facility. Due to increased demand, high product variety, and a push production system, the plant has suffered from excessive wastes, unorganized workstations, and unhealthy work environment. This has translated into increased production cost, frequent delays, and low workers morale. Under such conditions, it has become difficult, if not impossible, to implement effective continuous improvement studies. Hence, the lean project is aimed at diagnosing the production process, streamlining the workflow, removing/reducing process waste, cleaning the production environment, improving plant layout, and organizing workstations. 5S lean technology is utilized for achieving project objectives. The work was a combination of both culture changes and tangible/physical changes on the shop floor. The project has drastically changed the plant and developed the infrastructure for a successful implementation of continuous improvement as well as other best practices and quality initiatives.

Keywords: Kaizen, continuous improvement, Lean Technology, Work Methods, Work Standards

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1329336

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 4359

References:


[1] J. Pettersen, "Defining lean production: some conceptual and practical issues" in TQM Journal, 21(2), 2009, pp. 127-142.
[2] J. P. Womack,D. T. Jones, Lean thinking. Free Press, 2003.
[3] J. P. Womack, D. T. Jones, D. Roos,The Machine that Changed the World. Free Press, 2007.
[4] T. Ohno,Toyota Production System. Free Press, 1998.
[5] L. Wilson,How to Implement Lean Manufacturing. McGraw-Hill Professional, 2009.
[6] J. P. T. Mo, "The role of lean in the application of information technology to manufacturing" in Computers in Industry, 60(4), 2009, pp. 266-276.
[7] C. Ortiz, "Kaizen vs. Lean: Distinct but Related" in Metal Finishing, 108(1), 2010, pp. 50-51.
[8] S. A. Ruffa,Going Lean. AMACOM, 2008.
[9] C. Parrillis, B. Rosinski, 5S Implementation Manual: Starting Lean Manufacturing. W Publications, 2007.
[10] S. S. Chakravorty, "Six Sigma Programs: An Implementation Model" in International Journal of production Economics, 119(1), 2009, pp. 1- 16.