UNIVERSITY OF ENGINEERING AND TECHNOLOGY TAXILA

WSMC
LAB MODULE

SUBMITTED TO:
ENGR. ABDUL REHMAN
SUBMITTED BY:
SIDRA SAEED (17-IE-27)
FAIZA RAZA (17-IE-50)
M. LAEEQ (17-IE-17)
ZEESHAN (17-IE-49)
RAO ZARYAB (17-IE-23)
SOHAIB ASIM (17-IE-43)
Lab Name:To implement 6s methodology as a lean improvement tool to an organization
orworkstation
Course title: Work Study and Methods Engineering Total Marks: ____________

Practical No. Date of experiment performed: ____________

Course teacher/Lab Instructor: Engr. M. Abdul Rehman Date of marking: ____________
Student Name: ____________________________________________________

Marking Evaluation Sheet

Max. Obtained
Knowledge components Domain Taxonomy level Contribution
marks marks

1. Student has conducted the

experiment by practicing the Manipulate (P2) 10
hands-on skills. Psychomotor 70%
2. Student has achieved required
Precision (P3) 8
accuracy in performance.

3. Student has Followed the safety

instructions while performing Respond (A2) 3
the Experiment Affective 20%
4. Student has followed all the
timelines provided during the Valuing (A3) 2
lab session
5. Student has analyzed and Compare/evaluate
Cognitive 10% 2
compared the results.
(C4)

Total Marks
25

Signed by Course teacher/ Lab Instructor

TITLE:

To implement 6s methodology as a lean improvement tool to an

organization or workstation.
OBJECTIVES:
To reduce inventory.

To reduce searching time for parts/ equipment’s.

To reduce accidents.

To increase discipline relation with top management to employees to workers.

To neglect the failure and breakdowns of machines or material handling equipment (MHE).

To make safe and motivate working environment for improving the organization/industry
performance.

APPARATUS:
Stopwatch
Toolbox
Stationary Items/Tools

INTRODUCTION:
The practice of 6S is commonly used among the industries of the world in order to enhance
human capability and productivity. Our apparatus consists of a box which constitute all the items
required in that area and small boxes that are categorized according to the names of items.
Before the implementation all items are placed in unarranged order. After implementation by
students they are sorted in order with respect to their name designated. This comes under pre and
post analysis.
The six steps of 6S method are as follows:
1. Seiri(Sorting)
2. Seiton(Set in order)
3. Seiso(Shine)
4. Seiketsu(Standardization)
5. Shitsuke(Sustain)
6. Safety (Safety)

THEORY:
The 6S methodology utilizes the all resources and manpower in an efficient way to attain desired
results in the industry. This is a powerful technique to increase the individual performance as
well as overall performance in any working area. The 6S technique is giving a new standard to
our apparatus. All tools, materials and safety equipment are available in our apparatus. This
method improves the quality and safety of work environment in the manufacturing industries.

CASE DESCRIPTION:
A group of three members faced difficulty in making a sketch. They have placed all the
sketching materials into one box like erasers, sharpeners, pencils, pencil colours and paper pins.
While sketching, when they need any item they first have to search out from the box. This
consumes their time in sketching. For one sketch that normally takes 2 hour to complete, they are
taking 2.30 hours. In this way they have less demand fulfilment. And the customers have to face
time delay. In order to recover this avoidable delay, 6s methodology is implemented. In this
methodology, all the materials are arranged in a separated box and their maintenance is done
regularly. Following is the description of 6s methodology.
SORT:
We used “Red Tagging”, an effective visual method of identifying un-needed items in this phase.
In this method, labels or signs are used to identify two areas:
1. One area for the collection of unused items. If the item is not needed to do your job, discard it.
2. One area for tools or other items that are needed.

SET IN ORDER:
The objective of set in order was to achieve an efficient functional work environment layout by
placing everything in a specific place that will minimize search hassle when needed. For
example, put all the same size of keys together. The most important step in set in order is to tag
the name of tools and items so that everyone will know where the tools and items are present for
that they are looking without wasting time.

SHINE:
This is a concept to make everything in the workplace neat, shiny and clean for their better use
and long life. Clean workplace conditions are also important to member’s health, morale, and
safety. Put everything back in the correct place after cleaning.

STANDARDIZE:
Standardization is the way to help the company to set some rules and instructions to implement
the first three steps daily in the company. The rules may be regularly changed for to make better
working condition.

SUSTAIN:
The leader should make a checklist to make sure that everyone follows this step. It shows the
value of our project, members and cares about their success, which boost team members pride
and self-esteem.

SAFETY:
This is additional feature to the 5S method. Safety equipment includes helmet, safety jackets,
safety gloves, fire extinguishers etc. Make sure that the workers are constantly aware of the
values of safety and health in the workplace and therefore adopt preventive measures against
recognizable hazards.
METHODOLOGY:

Following are the steps to perform the experiment:

PRE-ANALYSIS:
1. Put the box on the table.

Figure 2: General box filled with all items.

2. One of the members should be selected to take the items from the table. Collect pencils and
start the stopwatch as shown in the figure. Note the time of picking pencils from the box.

3. Repeat the step no 2 for each of the given items and calculate the time.
4. Now prepare another box and make partition for each item.
Post Analysis:
Identify the needed and unneeded items from materials and keep only the essential items by
“Sorting”. The unneeded items are then discarded in a separate box. Also calculate its time
when we sort unneeded things.

Figure 4: box contains unwanted items.

Figure 5: Identification of unneeded items

6. In the second step “Set in Order”, place the regularly needed items in their relevant box.

Figure 6: All sketching materials are placed in their required boxes.

7. Then we perform “Shine” activity by keeping our workplace clean. We have to clean not for
beautification alone but with a sense of purpose as well.
 Figure 8: Workstation is cleaned after every task.
Figure 7: shine implementation

8. After shine, do “Standardization” in such a way to create best practices and to get each
team member to use the established best practices. Without a clear standard, there is no way
to monitor the improvements.

Figure 9: The tags are put at each box to represent as a standard of

placing the items at each box.

9. In this step of “Sustainability”, make a check list to help the leader to make sure whether
every member follows the rule to sustain or not. The leader has to check it on each day for
regular improvement and performance of the worker.
 Figure 10: Checklist

10. In this step of “Safety”, keep the worker and workplace safer by eliminating hazards. All the
required apparatus should be properky finished. Things like match stick, knife are removed
from the workstations.

Figure 11: safety implementation

11. Task will be performed in the group of six members.

12. Note the time taking by each steps in implementing 6s.
13. Now note the time taking to pick up items for sketching. This would take less time as
compared to before implementation steps.
OBSERVATIONS AND CALCULATION TABLE
Total Steps = 06

Total Items:
Pencils=8
Erasers=4
Sharpners=4
Color pencils=12
Paper Pins=20

Sorting Time= 1.07 sec

Setting Time in sec:

Items Pencils Colour Pencils Sharpeners Erasers Pins

Time (Sec) 8.86 8.77 7.43 6.67 24.3

Shining time= 5sec

Safety Time= 15 sec

Standardizing Time= 15 sec

Sustaining Time=25 sec

Pre-Analysis:

Time for picking pencil, eraser, sharpener, color pencils and paper pins = 23.58 seconds.

Post Analysis:

Picking up pencil, eraser, sharpener, color pencils and paper pins collectively take 7.34 seconds.

Explanation:

We did two experiments on this apparatus, one is before 6s implementation and other after
implementing 6s. We calculate time side by side and came to know that implementing 6s
required much less time. There is a huge difference between time values. This shows the
effectiveness of 6s in any workstation.
 Identify each step and write down their details:

Table 1 6s steps

PRE AND POST ANALYSIS:

6S PRE-ANALYSIS POST-ANALYSIS

SORT

SET IN ORDER
SHINE

STANDARDIZE

SUSTAIN
SAFETY
CHECKLISTLIST
CHECKING THE IMPLEMENTATION OF 6S ITEM SCORE
EVALUATOR NAME:
BEFORE AFTER

Distinguish between what is needed and not needed

SORT Have all unnecessary items been removed?

(Organization)
Have you placed tags for necessary items?

A place for everything and everything in its place

SET IN ORDER Is there a place for everything?

(Orderliness)
Is everything in its place?

Are locations obvious and easy to identify?

Cleaning and looking for ways to keep it clean

Are work areas, tools, table are free of dust?

SHINE
(Cleanliness) Are cleaning materials available and accessible?

Is everything put back after cleaning process?

Maintain and monitor for adherence

STANDARDIZE Are all standards known and visible?

(Adherence)
Are all visual displays up to date?

Rules to sustain
SUSTAIN
(Self-Discipline) Are all procedures being followed?

Maintaining a safe workplace

SAFETY Are workers known about usage of safety

(Zero incidents) equipment?
Is all safety equipment accessible and in range?

TOTAL SCORE
SAFETY INSTRUCTIONS:

1. Set the apparatus parallel to your posture. It makes easy for us to perform each activity.
2. Start and stop the stop watch carefully while starting and ending the activity.
3. Handle the material/ tools carefully. Do not use sharp tools. It can cause injury.
4. Make sure you perform the steps in a sequence way.
5. Trim the edges of boxes.
6 while sorting adjust the sections’ distance appropriately so that performer’s hands can be
easily move.

RESULTS AND DISCUSSIONS:

Q#1. Explain benefits of 6s in an organization?

 Reduce Operational Costs:

Some risks cannot be eliminated in most of the companies. Six Sigma methodology can provide
a road map that can drastically reduce an organization’s exposure to risks.

 Improve Efficiency or Timeliness:

To improve timeliness, Six Sigma projects can be targeted towards reducing the number of
machine setups or set-up hours in a manufacturing process

 Improve Customer Service:

Six Sigma projects can help identify the number of variations customers are experiencing, what
is driving that variation, and ultimately, how the number of dissatisfied customers can be
minimized.

 Improve Regulatory Compliance:

The first one is Finance & Audit in Regulatory Compliance, the second one is Information
technology, and the third one is Legal. Six Sigma projects can be undertaken in each of these
aspects; depending on the types of defects identified

Q#2. Discuss types of wastes?

Waste is often called “Muda.” List of wastes are as under:

 Waste in transport: Waste in transportation includes movement of people, tools, inventory,

equipment, or products further than necessary. Excessive movement of materials can lead to
product damage and defects.
 Excess Inventory:

Having more inventory than necessary to sustain a steady flow of work can lead to problems
including; product defects or damage materials, greater lead time in the production process, an
inefficient allocation of capital. Excess inventory can be caused by over-purchasing,
overproducing work in process (WIP), or producing more products than the customer needs.

 Motion:

The waste in motion includes any unnecessary movement of people, equipment, or machinery.
This includes walking, lifting, reaching, bending, stretching, and moving.

 Waiting:

The waste of waiting includes:

1) People waiting on material or equipment

2) Idle equipment

Waiting time is often caused by unevenness in the production stations and can result in excess
inventory and overproduction.

 Overproduction:

Overproduction occurs when manufacturing a product or an element of the product before it is

being asked for or required.

 Over-processing:

Over-processing refers to doing more work, adding more components, or having more steps in a
product or service than what is required by the customer.

 Defects:

Defects occurs when the product is not fit for use. This typically results in either reworking or
scrapping the product.

Q#3. What is lean?

A term developed by MIT researchers to describe companies which have implemented the Toyota
Production System. Lean are activities performed with a specific objective of minimizing inventory
related costs and activities.
CONCLUSION:
The 6S methodology is one of latest and modern method to gain a desired goal in every activity.
The 6S methodology rearranges the all resources and does every operation in a sequence to full
utilization of each resource. 6S is the key to organize a workplace for efficiency and decrease
wasting and optimize quality and productivity via monitoring an organized environment and
keeping the environment safe from accidents. After implementing6Sconcept, any organization
can achieve effective improving performances such as, reduced wastage, reduced defects,
increase productivity, less making accidents, improve workers/employees morale for work with
organization etc. Pre and post analysis clearly depicts that time will be less consumed if we
placed all items at their specific location.

COMMENTS:

The proceedings to activities clearly show that training of workers about the 6S rules is very
essential. The important task is to divide activities on some main steps and to maintain the
continuous improvement. The inspection is executed with the help of check list, which serves to
estimation of the workplace. Check list ensures you get your daily, weekly and monthly tasks
doneon time, helps you keep track of projects on deadline and ensures you are organized
throughout the day. We make pre and post analysis of each and every step of our activity which
clearly depicts the importance of 6s.