ENGINEERING PRACTICE

CHAPTER 1
1. Introduction
The origin of 5S was developed in Japan and it was derived from five Japanese words which c
(Sort), Seiton (Set in oder), Seiso (Shine), Seiketsu (Standardize) and Shitsuke (Sustain). The objectives
of 5S system are reduce waste and optimize productivity by maintaining a workplaces orderly and using
visual cues to achieve more consistent operational results. The target of 5S is to build up a safe and
comfort working environment by keeping the working area in order, neat and clean. Workers should
undergo the 5S system in their own working area.

The term “5S” stand for these five actions:

Sort Organize and throw away the unnecessary clutter

Set in order Arrange all items visually for ease of use
Shine Clean the work place so that the problems can be identified
Standardize Maintain everything in order and based on standard
Sustain Keep the improvements and let all the 5 actions as an habit daily

Table 1.1: Meanings of 5S systems

The 5S system is one of the most fundamental and widely applied components of lean
manufacturing. It was plays a main role in organizing a work space to ensure that is tidy, arranged
ergonomically, efficiency and effectiveness. For an example, it can eliminate the waste associated with
not having the right tools or documentation when we need them. The 5S system is a good starting point
for all improvement efforts aiming to drive out waste from manufacturing process. The implementation of
5S systems was the ways to reduce cost, improve quality, increase productivity and the safety
improvement can reduce the risk of accident.

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 ENGINEERING PRACTICE
1.1. Laboratory Background / Preparatory Plan
1.1.1. Laboratory Background
Our group working area is consisted of five different types of the machines. The
laboratory background is describes in the below.
This machine was useful when larger parts need to
be cut on a non-production basis. It was adjustable
variable down feed speeds and quick positioning
vise with adjustable jaws for 00-450 angles.

Figure 1.1:Horizontal Bandsaw, RF1018V

Each geared head metal drilling machine comes
fully guarded with halogen lights. This machine is
robust enough for milling, frilling and boring. This
machine equipped with a drawbar for threaded end-
mill tooling.

Figure 1.2: Geared Head Pedestal Drilling

Machine, Gate JFC-S005
This is the machine tool used for the complex
shaping of metal and solids materials. This machine
can perform a vast number of complex operations
such as slot cutting, planning, drilling, rebating and
else. Cutting fluid will be pumped to the cutting
site on order to cool and lubricate the cut, and to
sluice away the swarf.

Figure 1.3: Vertical Milling Machine, Gate

PBM-VS400

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This machine equipped with digital controller is
directly linked to the lead screw. Just use your
finger to select desired thread pitch on the
touchscreen display, the threads come out
absolutely precise and eliminate the problems with
specialized threads.

Figure 1.4: Precision High Speed Centre

Lathe, G-410-TCB
This machine is suited chamfering steel and cast
iron. Cutter can be axially adjusted for the using the
entire inserted-width.

Figure 1.5:Chamferring Machine

S11 provides economic manufacturing and
reconditioning for simple to precise and highly
complex precision tools. S11 was the specifically
developed for the tools grinding. The manually
controlled S11 is not only flexible but also
economic compared to CNC machines. The
Michael Decker offers a video measuring system
which can take over the strenuous tool focusing and
transfers the image to a color monitor.

Figure 1.6: Conventional Tools and Cutter

Grinder,S11, Michael Decker

Table 1.2: Laboratory Background

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1.1.2. Preparatory Plan

Step 1: Identifying the problems at the laboratory. Order the equipment needed to
improves or solves the problems.

Step 2: Separating the needed from the unneeded in order to eliminate the unwanted items from the work
area.

Step 3: Arranging the equipment in order so that can be easily picked for use. Clean the laboratory by
using the equipment.

Step 4: Labeling the names of tools, name of the machine, standard operation procedure and any safety
precaution sign.

Step 5: Creating a schedule to clean the machine and a check list to update the quantity and quality of the
tools time to time.

1.2 5S Introduction Setting up the Team and Lab Committees

1.2.1 5S Introduction

Figure1.7-5S Introduction

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 Remove unwanted items
 Prevent accumulation of unnecessary items
 Distribute the items which are need to be repaired.

Figure 1.8: SORT

 Arrange the items and dispose of them properly.
 Place the items properly so that the workflow is smooth

Figure 1.9: SET IN ORDER

 Clean the workplaces
 Prevent machinery and equipment deterioration

Figure 1.10: SHINE

 Make the abnormal conditions noticeable
 Label the tools and machinery equipment

Figure 1.11: STANDARDIZE

 Keep in working order
 Hold the gains and improve.

Figure 1.12: SUSTAIN

Table 1.3: 5S Introduction

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ENGINEERING PRACTICE