Implementing 5 s methodology as tool for improving efficiency

IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 03, 2015 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 214
Implementing ‘5-S Methodology’ as Tool for Improving Efficiency &
Performance of Delivery and Production Operations at Bajaj Steels
Industries Ltd
Sameet Dandawate1
Laukik P. Raut2
Praveen Talamale3
1
Student 2
Assistant Professor 3
General Manager
1,2
Department of Mechanical Engineering
1,2
GHRCE, Nagpur, India 3
Bajaj steels Industries Limited, Nagpur
Abstract— The Moto of this paper is to implement 5-s
Methodology in the Bajaj steels industries limited. This
paper contains 5-s action plan for the company. It aims at
increasing the productivity, reduction in the standard
production time, reduce wastage of resources and optimize
working procedure, proper work area management and
safety. The action plan contains various tools such as Line
of Balance Graph (LOB), Critical Ratio Scheduling (CRS),
symbols and bar graphs that will help the company in
understanding the plan in better way. Further, it shows
through inspection and audit that proper implementation of
5-s can lead to increase in productivity by 97 percent.
Installing and ensuring the proper usage of supply chain
management by using “5-s” management technique in the
assembly shop of Bajaj Steels Private ltd.
Keywords: supply chain management, line of balance graph,
critical ratio scheduling, management tool, 5-s management
tool, Total quality management
I. INTRODUCTION
A. Background of the Studies:
5-s technology indigenously developed in Japan aims at
reducing the wastage and optimizing productivity through
maintaining orderly workplace and organizing the work
tools, machines ina proper manner by using the 5-s. It
includes
1) Sort (Seiri) involves elimination of unnecessary
tools, improper machine arrangements and
cleanliness.
2) Orderliness (Seiton) arrange in chronological
manner.
3) Shine (Seiso) clean workspace.
4) Standardize (Seiketsu) installation of any standard
authenticated methodology.
5) Sustainability (Shitsuke) sustaining any
methodology forever to achieve more consistent
operational results.
Bajaj Steel Industries Limited is among the reputed
manufacturers, exporters and suppliers of cotton processing
equipment and many other types of equipment. In the
modern era of industrial sector where different competitors
pose a very stiff competition, every industrial organization
aims at improving the quality of the product and efficiency
of the production and delivery processes in every aspect that
comes under the total quality management (TQM). In the
frame of implementing the total quality management (TQM)
which primarily means continuous improvement, 5-s
methodology has gained lot of popularity. 5-s management
tool helps to create and maintain well-organized, clean and
high quality working place, tools & machines. Standardize
the authenticated procedures and sustaining them in the
industry. Implementing similar 5-s practices in the Bajaj
Steels to improve the performance of the industry and
increase the efficiency of the production and delivery
operations to gain the global profit. The industry is lacking
in different areas such as work area management,
cleanliness, tool management, supply chain management,
standardization of proper authenticated methodology,
sustainability and improper time management. Further 5-s
can also lead to the „just in time‟ management in the
industry. This paper describes various ways to bring 5-s in
actual practice at the Bajaj Steels Industries ltd.
B. Problem Definition:
The relationship between the top management and the staff
shows the ability to sustain 5-s in the industry. The company
is facing problem in implementing any quality improvement
technique due to lack of space available in their industry.
There is no awareness amongst the workers and the staff
regarding 5-s management tool. Implementing the 5-s
management methodology in the company is big task, as it
first needs to educate the workers and tell them the
importance of the 5-s methodology and its sustainability.
Implementing 5-s technique in such a small available space
and resources is a bit tough task.
II. OBJECTIVE OF THE STUDY
 Creating and maintaining well-organized and high
quality workplace.
 To ensure the proper cleanliness inside the industry
and implement a particular standardized routine of
processes and methods by using 5-s management
tool.
 Optimize the resources, work force and the
workspace. This will reduce the wastage of
resources in the industry.
 Promoting „5-s‟ awareness amongst the workers.
III. ADDITIONAL REQUIREMENTS IN BAJAJ STEELS
1) Installing Inspection department at every point
before sending any subpart to the next shop for
operation.
2) Maintaining chronological order in every shop, in
every routine and process.
3) Three types of storage are required
 Primary storage –(Natural Raw zero
operated sub parts)
 Secondary storage-(intermediately
operated machined parts)
 Tertiary storage-(fully completed
machined parts should be stored here
which are in excess as per requirement)

Implementing ‘5-S Methodology’ as Tool for Improving Efficiency & Performance of Delivery and Production Operations at Bajaj Steels Industries Ltd
(IJSRD/Vol. 3/Issue 03/2015/054)
4) Cleanliness in every shop of the industry.
5) Installation of Automated parts transferring system.
6) Work tool & work space management.
7) Removal or storage of unwanted or waste products.
8) Optimization of resources.
9) Usage of critical ratio, scheduling method & line of
balance graph analysis.
IV. CURRENT SCENARIO & DATA OF COMPANY
Currently the company is not able to satisfy the demand.
They do not have the standard working methodology. The
workers in the company are not aware of the norms thus
resulting in delay and less productivity.Table 1 shows the
standard time for assembling one cotton ginning machine. It
shows the data & statistics of the operations and assemblies
done in the Bajaj Steels Industries Limited.
Sr.
No.
Element
Cycle
Average time
(min)
Rating
Normal time
(min)
Allowances
Standard
time
(min)
1 2 3
1
Swing lever
assembly
10.1 11 9.8 10.3 0.93 9.6 20% 11.52
2
Cross bar
assembly
12 10 11.5 11.16 1.05 11.71 21% 14.16
3
Roller shaft
assembly
20.2 20 20.5 20.23 1.02 20.63 32% 27.23
4
Seed guard
assembly
12.5 10 11 11.16 1.3 14.50 23% 170835
5 Rail assembly 15 15.6 16 15.53 1.00 15053 34% 20.81
6
Beater shaft
assembly
15 16.1 16.7 15.9 0.75 11.925 35% 16.09
7
Gear box
assembly
5 5.5 6 5.5 0.97 5.335 30% 6.9
8
Gear box back
side
5.1 5.3 5.5 5.3 0.98 5.2 31% 6.81
9 Hub assembly 10.1 10.7 10.5 10.43 1.07 11.16 42% 15.84
10
Auto feeder
assembly
10.5 11 10.7 10.73 1.09 11.7 43% 16.73
11 Screw conveyor 9 9.5 10 9.5 1.10 10.45 44% 15.098
Total 168.973
Table 1: Standard Time for Assembling One Cotton Ginning Machine
Average Time = cycle time1 + cycle time2 + cycle time 3
Total allowance allowed = fatigue + contingency allowance
+ relaxation allowance on average = 32.37%
Standard time = normal time* allowance time = 168.973
Normal time = average time * rating
Table 2 shows value of rating that depends on the skill of
the worker
Skill Rating
Poor Below 0.65
Average 0.66 to 0.78
Above Average 0.79 to 1.00
Good 1.000 to 1.005
Excellent 1.006 to 1.5
Table 2: Rating of Worker
Following is the data for assembly of cotton
ginning machines/day
Total Productivity = Total output/ Total Input
Total Productivity = 2400000/ 636000= 3.77%
Table 3 shows the production cost of twenty four machines
which is being produced in one day.
Particulars Cost
Output = 24cotton
ginning machines
24×100000= 2400000 lacs/day
Cost of 1m/c= 100000
Human input (H.I.)
45workers
45×salary of one worker for this job
45×3000=135000/day
Capital input(CI) Re 16000/day
Energy input(EI) Re 50000/day
Other expenses (OE) Re 10,000
Material input(MI)
Re 4,25,000
Among 45workers each worker
having one tool kit + machines
Total input cost Re 636000 (HI+MI+OE+EI+CI)
Total output Re 2400000
Table 3: Input Output Cost
V. ACTION PLAN, IMPLEMENTING „5-S‟ AT BAJAJ STEELS
PRIVATE LTD
Fig. 1: The Basic 5-S Model Cycle
A. Seiri:
Seiri means sorting out the unwanted things and removing
those things. Sorting and removing the damaged machining
tools or subparts, which need additional treatment, and
storing them accordingly. This will help in producing high
quality production. Separating the tools and components
required for different machines such as tools required for
operating Jumbo and Golden Machine. Sorting out the

damaged machine parts or working tools such as (drilling
tools, cutting tools, slotting tools etc.) and disposing them to
proper recycling workshop to smoothen the workflow,
prevent confusion and create high quality products. Appoint
inspection department or cleaning department for this
activity. Differentiate the shops in the industry by borders
drawn with different colors. Removing or preventing
excessive utilization of work force, time and resources. Give
responsibility of all above activities to inspection
department to ensure its proper working.
B. Seiton:
Use differentcolorsfor bordering the different shops.
 Outline the machining by red color.
 Outline assembly shop by yellow color.
 Outline Automation shop by orange color.
 Delivery shop by green colored marking.
Drilling tools can arranged and differentiated
according to the number of threads in each tool. Similarly,
arrange other machining tools properly.
Fig. 2: Layout Suggested for Industry
Work flow path i.e. the direction in which the parts
are being transferred from one unit to next unit should be
one directional only. There should not be two directional
paths of the components as it creates mess and waste of time
&work force. The components should be passed in one-way
direction only in to maintain smooth workflow and prevent
waste of time and work force. Transfer the subparts after
machining operations are over to the assembly point as per
requirement. Supply chain management should be taken in
consideration while supplying sub components to the
assembly point i.e. (every subpart should be supplied in
equal proportion after proper time interval). In machining
shop, arrangethe lathe machines and other heavy machines
in chronological order as per the serial order of performing
the operations. Excessive subparts should be stored in
primary, secondary and tertiary storage accordingly as per
the amount of processing done on it.
1) Application of Seiton in Assembly Shop:
Appoint a fixed number of workers in the assembly shop.
Divide assembly shop in small sub sections where particular
number of workers can operate on a machine. Divide Total
assembly workspace in small work areas with proper
bordering to prevent mess and accidents. The worker should
also feel spacious and free while assembling the machine.
 E.g. 8hrs. shift= target is 48 machines
 If 60 workers are engaged in assembly shop
 Appoint 5workers to one sub section
 Time required by 5workers to complete 1
assembly=2hrs
 5workers +2hrs= 1 ginning machine
 So in 2hrs 12 machines can be assemble by the 60
workers
 Therefore, in 8hrs assembly of 48 machines is
easily possible.
Sec-1
5 workers
Sec-2 5workers
Sec-3
5 workers
Sec-4
5 workers
Sec-5
5 workers
Sec-6
5 workers
Sec-7
5 workers
Sec-8
5 workers
Sec-9
5 workers
Sec-10
5 workers
Sec-11
5 workers
Sec-12
5 workers
Table 4: Division of Total Assembly Space
Table 4 shows division of total assembly space of Bajaj
Steel ltd.
Therefore, above table divide 60workers in 12 sub
sections of the assembly shop.
Supply all the subparts to every section in
chronological order and with proper time management i.e.
(make the next part available in within the time required to
fit the previous part). This will maintain the workflow and
the chances of errors, delay time and reduce the wastage of
work force. Supply proper tools before the start of assembly
operation in every section of the assembly shop. Create
small storage place for keeping the tools available in every
section of the assembly shop so that the worker can work
with ease and high accuracy. After the assembly, the
machines should be stored in delivery hall in lots. This will
help in saving work force and time. The industry officials
can also use signals or lights to give indication. This will
maintain the smooth functioning within the industry and
save more time and energy. Separately store the components
of jumbo and golden machines in serial order so that there is
no problem faced at the time of dispatching. Install a proper
supply chain system in the industry to attain ease while
supplying components to the assembly shop.
C. Seiso (Cleanliness):
Cleanliness is very important part of any industry. Cleaning
department should perform cleaning operations after every
shift. This will help in creating proper working ambience for
the workers working in the next shift thus maintaining the
quality of the production. Servicing of the tools and man
handled machines should be done periodically and be made
mandatory. This will definitely help in maintaining good
accuracy and preparing high quality products. Perform
cleaning operation after every shift, properly arranging the
tools, machines and other completed components. Perform
cleaning operation after a fixed interval of time. This will
help in making proper working ambience for the workers.
Clean the waste products after the manufacturing of any
component.
Inspection department is responsible for inspecting
and cleaning operations. After every 8hours, the inspection
department should conduct cleaning activity.
D. Sieketsu (Standardization):
Standardization plays a very vital part in an industry.

 Installation of a standard authenticated procedure
including all the pre decided norms of the
company.
 Every worker should perform his/her work by
abiding to the standard authenticated procedure.
 Conducting counseling session for theworkers by
the industry people on how to implement the action
plan.
 Implementation of mock drills at the initial stages
within the industry for the workers to practice the
standard procedure.
 Evaluation of the processes by making check sheets
to inspect whether the workers are following the
standard action plan.
 Inspection department should perform the checking
operations after fixed interval of time.
 Formation of standard action plan by taking into
consideration the standard 5-s model cycle and
every worker should perform his /her work by
abiding to the standard procedure.
 Fix a certain time limit in which the worker has to
complete the operation.
 Display the standard action plan on the notice
board of each section so that the workers would
refer it in case they forget some step. This will help
in saving time and obtain high quality production.
Figure 3 shows the Standard procedure in a machining shop.
Fig. 3: Standard Procedure In A Machining Shop
In this way, apply standard procedures to other assemblies
to obtain on time high quality production. Here each step
can also be constrained by specifying time required for each
operation.
Fig. 4: Standard Procedure in Production Operation
Therefore roughly,one can easily produce 24pieces
6 hours easily. Apply such kind of standard procedures in
every shop. This will increase the efficiency of the
production and delivery processes and with great ease, one
can achieve the desired target.
E. Shitsuke (Sustainability):
Sustainability is one of the most important parameter or we
can say that it has to play a very important role in order to
keep the standard action plan in working forever.
Sustainability means to do the things without being told by
someone. Inspection department has the vital role to play in
order to sustain the standard action plan. Utilize check
sheets to inspect the proper following of the action plan.
Activity
list
day
1
day
2
day
3
day
4
day
5
day
6
day
7
Sorting
removal
of
unwante
d waste
products
Y N Y Y Y Y Y

Arranged
the
working
tools in
proper
manner
Y Y Y N Y Y Y
Cleaning
operation
performe
d
N N Y Y Y Y Y
Followed
the
standard
procedur
e
Y Y N N Y Y Y
Performe
d the
check list
operation
Y Y Y Y Y Y Y
Table 5: Checklist
Prepare similar checklist activities for the other
assemblies and processes to inspect the progress of the
industry and check whether the implemented action plan is
profitable or not.Depending upon the results of the check list
activity, warn the workers for the first time and then if they
repeat it next time penalize them for not following the
standard action plan. This will sustain the working of
standard action plan in the industry successfully.
VI. APPLYING LINE OF BALANCE (LOB) & CRITICAL RATIO
SCHEDULING IN BAJA STEELS INDUSTRIES LIMITED
Line of balance technique (LOB) is a method of production
control, which combines the features from Gantt chart and
CPM time chart with graphs of material requirement. It is
the most appropriate for assembly operations involving a
number of distinct components. LOB can be used to
schedule and control of a single batch (of the same job). The
following requirements should be satisfied,
1) There must be an identifiable stages I production at
which managerial control can be exerted.
2) The manufacturing times between these stages
must be known
3) Availability of delivery schedule
4) Resources can be varies as required
The application of line of balance technique
consists of the following stages:
1) A graphic representation of the delivery objective.
2) Activity on arrow (AOA) diagram to show logical
sequence and timing of activities of production.
3) Progress chart of current the status of component
completion
4) A line of balance drawn to shown the relationship
of component progress to the output needed.
LOB diagram is a representation of the state of the
production process at a specified time. For a particular
review period, it represents the progress of all activities
involved in the production and indicates if the delivery
schedule can bemet. For each individual activity, it shows
the current level of production against the
plannedproduction. Lob helps the management to identify
the activities, which are out of balance to take the corrective
action.
A. Steps in Line of Balance Technique:
Construct an AOA diagram to represent the logic in the
tasks, which make up the manufacture of the product.
 Carry out a reverse forward pass starting at time
zero with the final node, to calculate the equivalent
week number.
 Rank the activities in descending order of
equivalent week number, prepare an LOB diagram-
a time scaled network.
 Prepare a calendar and accumulated delivery
quantity table.
 From the calendar and LOB table, prepare an LOB
table showing the quantity of each activity which
should be completed by each week number. For
each week number this gives an LOB chart, and
over the life of the project at LOB table.
 LOB graph helps to locate the progress at any point
of time.
Now the Line of balance technique is applied in
assembly of one cotton ginning machine at Bajaj Steel ltd.
The overall assembly of the cotton ginning machines is
divided in small sub-assemblies of different component,
which are described below.On an average, the overall time
required for assembling one cotton-ginning machine is
2hours.
The table 6 shows time distribution for one section.
120mins/ per section i.e. 1- section (group of five workers)
will require 2hours for complete assembly of one cotton
ginning machine. Similarly, there are 12sections in assembly
shop so after first 2 hours of assembly, total 12machines will
be assembled and in the span of one shift, 48 machines will
be assembled with the rate of four machines/ section.
Sr.
No
Operation
Time
duration
1 Swing lever assembly 10min
2 Cross bar assembly 10min
3 Roller shaft assembly 20min
4 Seed guard assembly 10min
5 Rail assembly 15min
6 Beater shaft assembly 15min
7
Gear box& gear fitting assembly
front side
5min
8
Gear box& gear fitting assembly
backside
5min
9 Hub assembly 10min
10 Auto feeder assembly 10min
11
Screw conveyor & screw conveyor
drive
10min
Total time 120mins
Table 6: Time Wise Distribution of Sub Operations While
Assembling One Machine
Figure 5 shows the Line of Balance graph for assembly of a
cotton ginning machine.

Fig. 5: LOB Graph
In this way, Line of Balance technique is useful in
applying to various processes of the industry. This helps to
know the time-to-time status of the completion of any work
and to find out the wasted time for any particular activity or
after the activity.
B. Implementing Critical Ratio Scheduling at Bajaj Steels
Private Limited:
It is a technique for establishing and maintaining priorities
among the jobs in a factory. Critical ratio is an index and
sets relationships between when a product is required and
when it can be supplied.
Critical ratio= time the job is needed (Demand time)/ supply
lead time
For example,
Critical ratio = product is required in 20 days/ product can
be made available in 10 days
So critical ratio = 2
A critical ratio of 2 means that time available to
deliver the product is twice the time required to manufacture
the product.
Critical ratio Greater than one means that there is a
sufficient time and job can be completed ahead of the
schedule. Equal to one implies that job is just on schedule
and requires close watch. Less than one suggests that the job
is critical and needs to be expedited to complete on
schedule.
C. Advantages of Critical Ratio Scheduling:
 To fix up relative job priorities for scheduling.
 Status of each job is determined.
 Schedule can be adjusted automatically when there
changes in job demand and progress.
VII. RESULTS OBTAINED AFTER IMPLEMENTING 5-S AT
BAJAJ STEELS INDUSTRIES LIMITED
Sr. No. Element
Cycles
Average time (min) Rating Normal time (min)
1 2 3
1 Swing lever assembly 10.1 11 9.8 10.3 0.93 9.6
2 Cross bar assembly 12 10 11.5 11.16 1.05 11.71
3 Roller shaft assembly 20.2 20 20.5 20.23 1.02 20.63
4 Seed guard assembly 12.5 10 11 11.16 1.3 14.50
5 Rail assembly 15 15.6 16 15.53 1.00 15.053
6 Beater shaft assembly 15 16.1 16.7 15.9 0.75 11.925
7 Gear box assembly 5 5.5 6 5.5 0.97 5.335
8 Gear box back side 5.1 5.3 5.5 5.3 0.98 5.2
9 Hub assembly 10.1 10.7 10.5 10.43 1.07 11.16
10 Auto feeder assembly 10.5 11 10.7 10.73 1.09 11.7
11 Screw conveyor 9 9.5 10 9.5 1.10 10.45
Total 127.74
Table 7: Results obtained after implementing 5-s
A. Calculation of Standard Time for Assembling One
Cotton Ginning Machine:
Average time = cycle time1 + cycle time2 + cycle time 3
Normal time = average time × rating
Total allowances allowed = fatigue + contingency
allowances + relaxation allowances =15%
Standard time = normal time × allowances time = 146.91
min
B. Productivity after Implementation of 5-S:
Output = 48
cotton ginning
machines
24 × 100000 = 48,000,00 lacs/day
Cost of 1m/c= 1000,00
Human input
(H.I.)
60workers
60 × salary of one worker for this job
60 × 3000 = 180000/day
Capital input
(CI)
Re 16000/day

Energy input (EI) Re 50000/day
Other expenses
(OE)
Re 20000
Material input
(MI)
Re 380000
(3 tool kits + machine per section i.e. 36
tool kits in 12 sub sections of assembly
shop)
Total input Re 646000 (HI+CI+MI+OE+EI)
Total output Re 4800000
Table 8: Input Output Cost
Total Productivity = Total output/ Total Input
Total Productivity = 4800000/ 646000 = 7.43%
Figure 7 shows the change in productivity before and after
implementing 5-s method. It shows the productivity is
increased by 97%.
Fig. 6: Change of productivity
Table 9 shows the comparison of productivity, production
time and total output before and after applying 5s.
Parameters Before After
Productivity 3.77 7.47
Production time 168.75min 146.91min
Total output Re 2400000 Re 4800000
Table 9: Comparison of various parameters before and after
applying 5s
VIII. CONCLUSION
Thus in this way 5-S can be implemented in the Bajaj steels
limited to improve the productivity of the organization and
efficiency of production and delivery operations. 5-S is a
better tool that can benefit the company in improving their
performance. It can be applied to any working process
within the industry/company. Further to sustain the 5-S
action plan the company will have to do audit on fixed
interval of time so as to check whether the on-going action
plan is producing the desired results or not. In the audit, the
action plan can be amended according to the requirement of
the company. In this way, 5-S management technique leads
to TQM, can be used as an effective tool in improving the
organizational performance, and should be implemented in
all the branches of Bajaj Steels Limited to improve their
performance.
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