Because time was running out fast, immediate action had to be taken. The 5S method appeared to be the best solution to order, sort and clean the workshop with a very noticeable, visual impact for all employees and visitors.
As explained previously, no technical aspects are developed in this blog. So, let's discover what has been implemented.
5S means
As specified on the picture above, each department started sorting, classifying and cleaning. Everyone participated, with feedback and ideas welcomed on how we could start thinking about standardizing and sustaining this new organization.
Mechanical Department
 |
| Old mechanical tools storage system |
 |
| Old mechanical tools storage system |
 |
| New tool dashboard specific to a product family |
Production Department
 |
| Old machine tools storage |
 |
| New Storage organization |
Assembly Department
 |
| New configuration for assembly department |
Workshop
Offices
Conclusion
S1 (sort), S2 (stabilize) and S3 (shine) have been implemented successfully and everyone participated. S4 (standardize) and S5 (sustain) are the most difficult and need more time.
The method and the implementation program were easily accepted by the employees. Lots of Japanese industries are installed in the area so all methods coming from this country are welcomed as most of the employees have heard of them.
Investments/costs
We can say ZERO investment. Racks welded with rusty, raw material, obsolete parts in stock in good condition have been sold, office furniture (eg: cupboards) have been transferred to other departments.
The only purchases made are: plastic boxes, cupboards, cleaning tools, furniture. Handover
To keep everybody involved and up to date, the 5S Team program has been created. Every trimester, 1 employee from each department participates in a one-day "5S" auditing all over the factory. The group is managed by an Indonesian employee in charge of the safety. A report and suggestions of improvements are expected at the end of each session. Actions are taken to put in place the solutions.
To keep everybody involved and up to date, the 5S Team program has been created. Every trimester, 1 employee from each department participates in a one-day "5S" auditing all over the factory. The group is managed by an Indonesian employee in charge of the safety. A report and suggestions of improvements are expected at the end of each session. Actions are taken to put in place the solutions.
