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A case study concerning the 5S The 5S lean

technique
lean technique in a scientific
equipment
manufacturing company 339
Shaman Gupta and Pankaj Chandna Received 3 January 2020
Revised 23 February 2020
Department of Mechanical Engineering, National Institute of Technology, Accepted 5 March 2020
Kurukshetra, India

Abstract
Purpose – This paper’s purpose is to help a scientific equipment company make use of the 5S tool on the shop
floor so that the organization can become progressively beneficial and increasingly productive.
Design/methodology/approach – The organization has adopted a simple approach for making a suitable
team for 5S tool implementation at the workplace. After that, they have used three types of data-collection
methods so that these methods could help in the correct introduction of the 5S tool in the business workplace.
They have also analysed the regression analysis with the genetic algorithm for the audit scores to predict the
behaviour of 5S implementation in the coming weeks.
Findings – In this case study, it has been found after the suitable analysis that the 5S tool implementation has
resulted in the overall benefits of the workplace. The major benefit achieved with the 5S tool is that the
searching time for the tool in the workplace has been improved significantly. Also, the safety level is increased.
The 5S audit has been carried out in the workplace and the audit score has been improved from the level of 6
scores (in week 1) to 72 score (in week 24).
Practical implications – 5S tool has emerged as an incredible asset and it tends to be actualized in any of the
ventures whether it is of a miniature, small, medium or large scale industry. The 5S tool can be applied
horizontally at a large scale and it can be applied to almost all the workstations in the workplace.
Originality/value – The presented productions and contextual investigation for the 5S tool will be helpful
and useful for all the analysts, experts and all other people who are worried about this subject of the 5S tool and
its implementation in the organization.
Keywords Practical applications of grey models, Lean manufacturing, 5S
Paper type Case study

1. Introduction
1.1 Introduction to lean manufacturing
Lean simply means to minimize or eliminate wastes and enable proper utilisation of resources
which in turn adds value to customers (Markova and Markov, 2017). Inventory is considered
as a significant source so a company should eradicate or minimize work-in-process or
completed parts of inventory because these do not add any cost to the product and when
inventory is minimized the problems which were unseen can be solved easily.
Seven types of wastes were being identified as a result of the production process in Toyota
which are discussed further (El-Namrouty, 2013):
(1) Overproduction: Overproduction is a kind of waste. When one produces more than the
requirements of the customer then it is termed as overproduction. Overproduction of
materials can take up storage and space and if not stored properly may get damaged.
Grey Systems: Theory and
(2) Defects: When a defective product has been created the materials that were used will Application
be a complete waste. Also, there will be late delivery of products because the product Vol. 10 No. 3, 2020
pp. 339-357
will need to be produced again which in turn also use labour so defects are also © Emerald Publishing Limited
2043-9377
considered as waste. DOI 10.1108/GS-01-2020-0004
GS (3) Inventory: The raw resources which are stocked work-in-process and stocked finished
10,3 goods are inventory. Extra inventory always results in higher inventory costs as
extra storage space is required and therefore it is also considered as a waste.
(4) Transportation: Sometimes transportation is difficult due to the distance and many
products get damaged because of not handling them properly.
(5) Waiting: When time is not being used effectively then one has to wait for the products
340 to get delivered. Workers do not do work on time and there are delays in processing so
this is a waste. This wasting of time can be overcome by giving the employees proper
training sessions from time to time.
(6) Motion: Motion is considered as waste because sometimes workers may move around
other places without doing their own work and as a result, there is a delay in
production.
(7) Over-processing: Over-processing refers to unnecessary polishing of finished goods
which are not required and which even customers will not notice. So, this is also
considered as waste.

1.2 Introduction to 5S
5S is a very useful manufacturing tool for an organization. It is easy in implementation and
leads to successful results or outcomes to the company. This helps the company in
organizing, maintaining cleanliness, standardization of work and smooth functioning of
work. All these activities are important activities for any manufacturing industry. The
organization implementing this tool is considered as superior to others present in the market
and attracts more projects and investment in an organization (Gupta and Chandna, 2019).
5S lean manufacturing tool stands for:
(1) Sort
(2) Set in order
(3) Shine
(4) Standardize
(5) Sustain
Let us now understand in brief about all these 5S tools or steps that are as follows (Gupta and
Jain, 2015):
(1) Sort: Before going in the depth into the meaning of this term let us understand the
basic meaning which says that, “it is a set of things or people belonging to the same
category or nature.”. This is explained as everything belonging to the same nature
should be categorised at one place which reduces the time of moving and shifting of
people and material as well as reduces wastage.
(2) Set in order: Now, the next step is to set all the things in order. This leads to setting a
specific place for everything and all the things in its place. This helps the employees
and its users in getting things or materials at one place and in easy terms. It also
reduces the mess of things and work. It also increases the effectiveness of
performance as the work is now visible in more easy terms and avoids its repetition.
(3) Shine: Shine means to glow or something which is sparkling. This can only be
achieved through cleanliness. Like anything, this is clean or kept in a clean place; this
 also increases its demand and also reduces any other damage. In an organization, The 5S lean
cleanliness is very important. At the workplace, people working on the machine or at technique
the field should be clean. This helps in the protection of workers from any type of
infection as well protecting the material from damage.
(4) Standardize: The term standardize means setting the bar or benchmark by
organizations to maintain the quality of their products. In manufacturing, the
material bought to manufacture or for processing should be according to the 341
organization standards. These standards help the organization in maintaining
quality. This also helps the company in achieving the trust of the company. These
standards are mostly fixed by the company but at times for the protection of the
consumers from adulteration, these standards are set by the governing authority.
These standards help in maintaining and improving the standard of living of the
society.
(5) Sustain: The term sustains means to strengthen something or someone.
In manufacturing terms, sustain is to continuously follow the same thing again
and again. For any organization to work it is very important that it does not change
its methods of doing work very frequently. Thus, in this step, the organization should
on a daily or routine basis follow all the 5S steps for better results and outcomes in an
organization.

2. Literature review
2.1 Lean manufacturing
Lean manufacturing assists in improving the production process and increase the Employee
Job Satisfaction (Minh et al., 2019). Lean Manufacturing is different from Traditional
Manufacturing. Traditional Manufacturing depends on the Inventory of the System while the
Lean Manufacturing considers inventory as the waste. Knowing the difference between Lean
and Traditional Manufacturing is very necessary for the Organization to apply lean
practices. The market is becoming flexible every day, to know the market dynamics is a very
necessary factor. The Lean Manufacturing believes that the customers will pay for the
services they receive, not for the mistakes (Mascarenhas et al., 2019).
Chadha et al. (2012) in his studies on Lean implementation in the healthcare in Hospitals
witnessed an advanced technique drift, increased ability and reduced emergency department
period of life for all patient lessons. No modifications in resource availability and protection or
high-quality troubles occurred in the course of the implementation of the lean method.
Jimenez et al. (2012) in his examination stated that Lean production was a step closer to a
new generation in production structures. It is a far running philosophy designed to supply
higher merchandise with few available resources to live in this cut-throat opposition. At the
start, LM was designed to produce motors in Japan, but its foremost strategies have been
implemented to an extensive variety of other processes in both offerings and production.
Lean production with Value stream mapping has been applied to the Rioja wine area. The
operating plan is categorized into degrees of changes to be made. In the first loop, the
regulator manner is stepped forward, then the second loop is used to design the uncooked-
materials reception structures with suppliers, and the closing loop improves the drift between
reception in the vineyard and bottling method. The study results in inventory discount
from 8 to 16%, production lead time discount from 50 to 65%, appropriate information
management and removal of the redundant statistics, and the usage of superior technologies.
Muslimen et al. (2011) in his studies on lean production implementation in a Malaysian
automobile additives producer centred on reducing the level of stock. After lowering the
inventory stage, the business enterprise was able to lessen different varieties of wastes.
GS Rose et al. (2011) in his research on Lean production implementation in SMEs witnessed
10,3 that there had been 17 lean practices that will be taken into consideration are possible and
relevant to the SME traits. The proposed practices had been based on three categories: least
investment, possible to apply in SME and encouraged by means of researchers. The practices
are 5s, visual manipulation and show, SPC, pleasant circle observed with other practices
along with Kanban and small lot sizes.
Mehta et al. (2012) in his observation for Gajara Gears Ltd found that Lean production
342 device Kaizen reduced the problem of wastage of broaching oil in the course of reloading
in the trolley after broaching. 5s, every other device of lean production focuses on
powerful workplace company which includes arranging the document of the accounting
section, arranging exchange gear in a separate rack and tool association in separate
hangers. The benefits achieved by using imposing this have been discounted in seek
time, travel time and visual manipulate. The success of Lean production relies upon
coordination and combination of various equipment and strategies. There are sure
obstacles inside the implementation of Lean production which may be conquered by
means of successful planning. The biggest obstacle is the non-recognition of Lean
manufacturing as an effective tool. Inside the international of globalization, all groups
attempt to enhance productiveness and increase the usage of commercial engineering
techniques. It is very crucial to understand the economic benefits of Lean production by
the businesses.
Apreutesei et al. (2010) concluded that Lean production is a supplement to fixed gear and
techniques. It requires a brand new, non-traditional manner of searching for things. This
involves adopting the philosophy and way of life of lean, in which all employees constantly
search for methods of enhancement. It also stated that agencies have to keep inventories on
the minimum level because excess inventories will result in better carrying fees and wastes.
Therefore, Lean tools along with Kanban, Poka-yoke and Kaizen are used to reduce seven
kinds of wastes (Muda) at some point of a manufacturing system.
Behrouzi and Wong (2011) in their look on lean performance assessment of manufacturing
systems by way of using Fuzzy membership values witnessed that Waste elimination and
J1T had been recognized because of the most critical additives of lean performance.
Vera et al. (2011) concluded that converting marketplace needs and reducing
competing manufacturing corporations to keep their manufacturing strategies green by
using steady enhancements of their businesses. Operating from the angle of the client
who consumes products or services, “value” is described as any action or system that a
purchaser might be willing to pay for. Lean manufacturing is a usual system control
philosophy derived ordinarily from the Toyota manufacturing machine. This results in a
boom in safety, space utilization, production, and drastic reduction waste, defects and
errors.
Singh et al. (2009) found in their investigation that recessionary time is the ideal
opportunity for enterprises to pursue lean rules and to investigate their business affix from
crude material to the end client so as to expel a wide range of waste. A portion of the rules
were: diminished piece and waste which unquestionably improves efficiency, TQM can be
embraced to diminish dismissal because of low quality and it can increase benefits, Pareto’s
standards can be received for stratification and distinguishing proof of products with the
most waste to cut expense and six sigma procedures can be utilized in an administration
industry to chop down expenses.
Singh et al. (2010) conducted his review on the degree for lean execution in 127 Indian
enterprises. In the wake of getting a reaction from 127 ventures, factor investigation was
conducted and 26 lean issues were diminished into five general classifications and were
positioned in diminishing request of their use in the Indian business: market issues, client
issues, provider issues, authoritative issues and top administration issues.
2.2 5S The 5S lean
5S is a lean method framework that is used to optimize productivity and simultaneously technique
reduce the waste from processes by maintaining the workplace in an orderly manner
(Tkhorikov and Zakharov, 2019). 5S is used to maintain a consistent operational outcome and
implementation of their lean method leads to having an organized and waste-free workplace
(Katare and Yadav, 2019).
Rahimi et al. (2013) utilized 5s segments for the division of youth and sports of Isfahan
physical training association. The examination showed that the organization needs to 343
improve the degree of systemization in the workplace. Systemization is the organization
prompts increment in the resisting condition and reduction of the unsafe advantages. So as
indicated by the significant job of this subject and as a result of the lower level of
institutionalization in the workplace of game and energy of Isfahan and for improving the
nature of the work and expanding the viability of the organs, this office needs to utilize the
new and successful approaches to build the degree of institutionalization.
Young (2014) actualized 5S in medicinal services administrations. The insightful writing
up to June 2014 was searched through the ProQuest, PubMed Google Scholar databases. Data
around 5S, Lean, approaches to execute 5S in medicinal services settings, utilization of 5S in
social insurance, blends of 5S and different apparatuses and recommendations to upgrade
achievement of 5S in human services administrations were assessed. Results demonstrated
that 5S can be connected to social insurance administrations with useful impacts, for
example, cleaner, sorted out, effective work environments for improved security and
expanded efficiency; the decrease of stock and supply expenses and recovering of profitable
spaces and limiting overhead expenses and keeping up 5s is a key to progress.
Gupta and Jain (2014) showed the utilization of 5s and Kaizen in a little scale fabricating
association. Usage of 5s and Kaizen brings about expanded proficiency and adequacy in the
procedures, improved perceived ability of the procedure, improved assurance and well-being
of the workers, decreased deferrals, looking through time and hazardous conditions.
Therefore to make fruitful 5S and kaizen framework the most significant components are
interest, responsibility and backing from the top-level administration.
Rosas et al. (2010) implemented 5s in 66 Mexican businesses and found that greater
dedication from the top control is vital to guide inside the creation of an organizational
tradition and 5S exercise must be covered inside the strategic making plans of the business
enterprise. In addition, education aims to beautify the notion of 5S practice and undertakes it
as a way of life in place of a management device. Furthermore, to enhance the 5S
implementation the following features must be included: employees’ dedication with the 5S
practice; the layout of official verbal exchange channels to recognize personnel suggestions to
enhance their jobs; great and continuous improvement orientation of all sports and
operations is vital.
Khamis et al. (2009) showed the use of 5s in two medium-scale organizations, A and B, in
Malaysia and overviewed that 5S practice is a viable system that can improve housekeeping,
ecological execution and well-being and security models in a coordinated all-encompassing
way. Powerful usage of the 5S action relies upon the responsibility of the top-level
administration, all-out contribution of the staff at all levels inside the organization, capacity
and foundation of the business, attention is given to the 5S movement and lastly the
preparation directed at the association in executing the 5S rehearses.
Kumar et al. (2007) led an examination in the Grindwell Norton Company. The information
on the exhibition of 5-S groups from Grindwell Norton was accumulated. This information
was substituted in the Questionnaire for Corrective Feedback Approaches (QCFAs) and the
money related bookkeeping articulations were created. The writing audit prompted the
finding that 5-S could be utilized as an intertwining gadget for conglomerating world-class
ideal models, for example, all-out quality administration (TQM) and quality circles (QCs). The
GS pragmatic usage study uncovered the similarity of utilizing QCFAS for monetarily
10,3 bookkeeping 5-S groups.
Ho and Cicmil (1996) depicted the use of the 5s approach in two organizations. The SIRIM
organization case exhibits how the 5s was effectively actualized in an enormous association
which therefore turned into a benchmark for others to pursue. The Wellex organization case
demonstrates that the 5s culture is widespread and can be identified with any work if there is
a pledge to the normal target and furthermore its profitability expanded by 26% with
344 turnover surpassing US$23 million.
(1) The objectives and research questions:
The organization chosen for this study is located in Saha, Haryana, India. The organization is
a leading manufacturer of scientific equipments. The main products of the company are
aerosol disinfectors and autoclaves. The company turnover is around 100 million and
potential customers include many leading hospitals around India. The major objective behind
conducting the research is to ensure that the 5S method is successfully implemented in the
company’s shop floor. It has to be ensured that the 5S method and lean structure are
incorporated in the daily routine work of employees once it is implemented. As far as the
concept of going lean, it can be better understood through going through these essential
questions and finding the answers of the same. These questions include:
Q.1. Formation of the lean working environment inside the organization?
Q.2. How the incorporation of lean structure into the routine-based operation of
employees will be done?
Q.3. How employees will be involved in the creation of the 5S method and how it will be
made to pertain and continue to last for long?
Q.4. How beneficial will 5S prove for the business?

3. Methodology
A “research method” can be defined as the systematically taken and orderly approach in
order to collect and analyse the data and extract the information from the data. As per the
definition given by Kothari (2011)), these are the methods or techniques that are used for
research purpose. These include analytical tools and questionnaire etc. The research
methodology can be seen as not only talking about the methods but also the realization of
their positive results over a wider scope while understanding the logic used. It includes
knowing why a particular method is used or not used. The research may be evaluated by its
researcher or an external agent too.
The action-based approach is being used in this methodology as theory is practically done
immediately after coming across. It was January 2019 when the idea for the project was first
generated by the researchers while attempting to find a topic for the research. And it was in
ending June 2019, when the project idea was finally presented to the company’s manager who
responded in positive. This gave the breakthrough to the project and a 5S specialist was
communicated the main goals expected. The organizational expert in the 5S method was
made to hold a seminar demonstrating the 5S method to the researchers and other concerned
stakeholders. The seminar provided a clear understanding to researchers about the main
concepts of 5S and how the system was to be implemented into the shop floor environment.
The creation of a project plan started along with the organization of the project in July 2019.
Tools like SWOT analysis and stakeholders’ chart, to identify the related parties, were
prescribed to be created by the researcher for the 5S method while conducting the research.
Even though the 5S method required the main practical part, but research was also used for The 5S lean
lean to be able to gain a better understanding of lean thinking and its related aspects. technique
3.1 Data collection in the organization
Data has been collected by personal interaction with a person related to working on the shop
floor, checking of previous records and performance of activities has been observed.
345
4. 5S implementation steps
Steps taken for the implementation of 5S are discussed further.

4.1 Step 1: Top management’s support in implementing 5S

The top management created an environment to support the introduction of 5S. This made
the change to be implemented without much resistance. The top management visited the
shop floor following the 5S principles to understand the steps taken and the results derived
from the step as benefits. 5S was implemented by undertaking training programs at
organizational levels and incorporating the objectives in the newsletters and magazines for a
better understanding of the benefits and principles.

4.2 Step 2: Launching an education and training program

The 5S education program was launched covering stories from the successful
implementation of 5S. The employees were made to join the program and educated about
the 5S implementation by highlighting their benefits. This brought acceptability in all
employees towards the implementation. The training program helped in improving the work
environment making it safer and encouraging, working as a platform for sharing the
innovative ideas, informing others about the change in environment, enhancing employees’
skills for better performance, improving operational efficiency for improved productivity,
empowering employees and addressing their time difficulties, involving employees in the
problem-solving process and increasing efficiency and effectiveness on a continuous basis.
The information about how the 5S works, its implementation process, its benefits and
duration are understood by collecting information on it. This information is collected from
books, conferences, seminars and the Internet.

4.3 Step 3: Organizational structure plan

5S as an organization is very much focused on sustainability and group working
environment. It believes that when people work in a group the chances of the project’s
success are much better and many a time certain. Creation of the 5S group is based on the
principle of respect and equality for all. It is also visible in its establishment of the 5S group as
it has members who are either working at the bottom level or at the top level. Such an
inclusive environment at the 5S group encouraged and motivated all the members to work
towards a common goal and objective.

4.4 Step 4: Formulating 5S policies and goals

Like many organizations, the 5S group also has very carefully drafted its policies as a goal to
meet their critical business objectives as mentioned here.
(1) Profit growth
(2) Holistic growth from the top to the bottom
(3) Promoting a healthy work environment across the organization
GS The 5S group is aligned with its objective to create a leaner organization that is inclined
10,3 towards cost reduction rather than cost-cutting which is a more painful and temporary
method unsuitable in the long run. The reasons here for following cost-reducing technique by
5S are:
(1) It is people-friendly and thus accepted easily.
(2) It puts positive impacts on the group in the longer run.
346
(3) Helps the organization to use resources efficiently.
(4) Improves processes and output significantly.
The 5S group believes that to attain the desired goals and objective it is very important to
understand the practical scenario and accordingly design policies and goals. Thus, the 5S
group has carefully analysed the actual situations and at the same time it has selected those
goals that are practically possible to achieve, seem realistic and can be measured. Also, it has
made sure that the people involved in this exercise of policies formulation and goal setting
should be very clear about what they are doing.

4.5 Step 5 - Master plan for 5S deployment and its presentation

The 5S group of an organization should be following a correct approach in developing a
master plan for its implementation. To make that happen we helped people to develop a
flawless master plan. We first made a visit to the company site and did some exercise to
understand the company as a whole unit.
(1) Understanding manufacturing and operations processes.
(2) The tools and equipment used by workers (type, function, associated problems and
losses, if any).
(3) Interactions with employees to understand their source of inspiration and their
attitude etc.
A consultant along with plant personnel created a presentation for management including
various interesting questions, answers and observations based on the above approach.
(1) Understanding the plant’s actual condition.
(2) Expectations from the 5S program in terms of costs and benefits.
(3) How will 5S be implemented?
(4) What shall be sequenced for implementation?
(5) Finalizing the strategy for implementation.
(6) Monthly review and audit structure for the 5S program.
Plant personnel who were responsible for preparing a presentation for management used
input from various sources such as seminars, meetings, conferences and plant visits etc.
In the end, the presentation showed recommendations to install a 5S program.
The result of this presentation was positive as management accepted the
recommendations given to them for the 5S program. Management also decided to create a
support structure, responsible coordinator to get the 5S program implemented. It also
proposed to carry out training and feasibility study to get effective program implementation.
The plan has also included even the small details as to what training is required and what are
the resources needed for training people and also the technical support they need for this.
4.6 Step 6: Feasibility study and its presentation The 5S lean
Successful installation of any program in an organisation is mainly based on the rate of technique
motivation by the employees to undertake the installation. In order to develop a baseline
for the 5s programme installation the company undertook a feasibility study, which will
help the management to evaluate the result as well as the progress of installation and will
even help in formulation of goals. This feasibility study involves checking the present
status of the equipment and forecasting present and future status of plant activities and
the surrounding environment, making an evaluation of required skilled human resources, 347
plant cleanliness and orderliness, the overall culture of the plant to make sure that it will
support 5s installation programme. Then the outcome of the feasibility study is presented
in front of the management and union, which agreed to make a pilot installation at one of
the sections.

4.7 Step 7: Pilot installation

At this stage, it was kept in mind that pilot installation should be conducted in that area which
required major improvements and had a chance of giving quick success, and it covered
around 15–30% of plant equipment at the same time employees of a given area were imparted
with required skill and knowledge development programme to proceed with 5s installation.
Resources were made available to adopt 5S improvement at the workplace, here teams were
formulated to identify and mitigate the problems.
Pilot installation went through a feasibility study covering five stages of 5s over a period
of 8–9 weeks. Each team was allotted particular activities with set goals. In the end, the whole
process went well and gave positive results and paved the way for the installation of 5s for the
whole organisation.

4.8 Step 8: Plant wide installation

The main objective of 5s implantation was to reduce the cost and make proper utilisation of
resources. As the pilot installation gave position results the management decided to install
the 5s programme for the whole plant in 2019.
For step-by-step implementation of the 5s plan, a coordinator from each sector was
appointed and they were organised in a structured manner to implement the plan, the
review was conducted monthly in a department wise manner and even by the top
management so that to make early identification of any bottlenecks in programme
installation.

4.9 Step 9: Progress audit

The certification for 5S is achieved after completing the progress audit. Generally, the
progress audit is the last step before the certification. The audit identifies discrepancies
as well as opportunities for successful completion of 5S. The audit is conducted in two
parts: theoretical and practical. The theoretical part is completed using the data and the
practical part is conducted in the plant. After the launch of the 5S program, the progress
audit usually was done in the following 6 months. The progress audit determines the
following effects.
(1) Whether the activities for equipment improvements are executed as per the
scheduling.
(2) Whether the documentation is done for the improved equipment condition.
(3) Whether the planned level of skills is achieved.
GS 4.10 Step 10: 5S certification and award
10,3 5S certification is important, as it reflects the improved quality of product and equipment as
well as the procedures followed for equipment maintenance. It reflects the efforts of the
organization towards quality commitments. 5S is an international certification, which has a
strict set of requirements for certification.
5S award from the Quality Circle Federation of India (QCFI) is awarded after 5S
installation, and it is the most rewarding step of the whole process. When an organization
348 possesses this award, it certifies the plant quality in terms of productivity, product quality,
and equipment quality. Moreover, it certifies that the organization has a teamwork-based
organizational culture. The management of the organization has a plan to get the certification
from Quality Circle Federation of India (QCFI) in the near future.

5. Case study
Tables 1–4 represents before and after pictures of 5S implementation on the shop floor in the
organisation.

5S sheet
Company name ABC

Objective To increases the safety of worker

Problem The safety of workers is less due to lose wiring and the
meter boxes are kept open
Problem analysis The chances of any accident such as electric shock
Loose wiring in the meter boxes
Root cause There is no cover for electric meter
Remedy Electric meter covered so chances of any miss-happening
are reduced
Action Provide cover to meter
Before After

Benefits
Direct: - Indirect: -
Table 1. (1) Safety of worker increased (1) Safer work environment
5S sheet 1 (2) Chance of short circuiting reduces (2) Accident rate decreases
5S sheet
The 5S lean
Company name ABC technique
Objective To protect the material from damage and avoid mixing of
semi-finish
Problem Wastage of time in identifying the needed material because
finished and non-finished materials get mixed. The finished
work pieces also sometimes get damage on their finished 349
surfaces while lying on the floor or when they come in contact
with the rough non-finished work pieces
Problem analysis Difficulty in identifying the finished and non-finished work
pieces because both get mixed together when they are lying at
same place on floor
Root cause There is no bin for finished and non-finished material. They
are just lying on the floor
Remedy Place separate bins for finished and non- finished materials
Action Use bins for proper keeping
Before After

Benefits
Direct: - Indirect: -
(1) Material search time is eliminated (1) Safe work environment
(2) Better housekeeping (2) Cleanliness in the machine shop increases
(3) Easy in material handling (3) Material rejection is also eliminated
Horizontal development Table 2.
1. Implement for all work stations 5S sheet 2

6. 5S audit
For better execution of 5S exercises under the organization and the presentation of controls in
a normal way, the quality administration division’s architects have been charged. 5S
exercises connected in the get together branch of the peered toward organization have been
assessed for about six months and the structures have been filled because of the week-by-
week schedule controls. Scores of all weeks are summed up. So week after week complete
evaluation scores are gotten and the appraisals are made through mirroring the week by
week scores on the designs. In the examination, the information on these structures has been
utilized and the investigation is attempted to be performed through watching the applications
inside, the organization. The five evaluation inquiries have been readied and 5S appraisal
structure has been readied. For answers to be given to these inquiries in every week, appraisal
scores as 0 5 Very awful, 1 5 Bad 2 5 Average 3 5 Good and 4 5 Very great have been
determined.
GS 5S sheet
10,3 Company name ABC

Objective To protect the milling cutter faces from damage

Problem Damage of face due to improper keeping
Problem analysis Operators keep milling cutters in a box and when these
cutters come in contact with each other, the edges get
350 damaged
Operators waste their time in searching the exact size cutter.
Operates keep milling cutters here and there
Wastage of time
Root cause Milling cutters are not placed in a proper manner
Workers are not good in housekeeping
Remedy A place for milling cutters and every cutter is in its place
Action Use a shadow board for milling cutters
Before After

Benefits
Direct: -
(1) Tool search time is eliminated
(2) Better housekeeping
(3) Easy in material handling
Indirect: -
(1) safer work environment
(2) Cleanliness in the machine shop increase
(3) Employee motivation and moral is increased

Table 3. Horizontal deployment

5S sheet 3 I. Implement for all work stations

6.1 5S audit results

Table 5 represents 5S weekly total scores and Table 6 represents 5S audit check sheet form of
week 4.

7. Regression analysis with genetic algorithm

The number of analysts utilized linear regression examination for the analysis of the
connection between the process and response parameters. It is utilized for the
demonstrating of the procedure, where one response is influenced by the number of
parameters (Cetin et al., 2011; Sharma et al., 2019). The tools used for computations are
MATLAB for genetic algorithm and Minitab for regression analysis. In the present study,
linear regression relationship as in equation (1) was derived for the investigation of total 5S
scores against week. The regression analysis and genetic algorithm depicting the need of
5S sheet
The 5S lean
Company name ABC technique
Objective Avoid the mixing of screws and nuts to save searching time
Problem Operators waste their time to search the screws and nuts
Trouble finding out the screws and nuts of the exact size at
the time of requirement
Problem analysis Operators are in the habit of careless up-keeping of screws 351
and nut
Nuts and screws are kept wrapped in a paper or in polythene
packets
Root cause Places for screws and nuts are not defined
Remedy All screws and nuts are placed in container according to their
size
Action Use plastic containers for screws and nuts
Before After

Benefits
Direct: - Indirect: -
(1) Search time is eliminated (1) Effective use of space
(2) Better housekeeping (2) Cleanliness in the machine shop increases
(3) Clean work table (3) Employee motivation and moral are increased
Horizontal deployment Table 4.
I. Implement for all work stations 5S sheet 4

this analysis is to find the equation which suggests as no of week’s increases, the 5S score
gets improved. It means we get better 5S implementation results as the number of weeks
increases.
Total Score ¼ 20:43 þ 1:742 ðweekÞ (1)

Figure 1 represents the normality plot, residual versus fit value, histogram and time variance
study. It is evident from the figure that all the residuals fall on the straight line that verifies
the normality test for regression. Other tests are also found to represent the goodness of
results.
GS 5S activities (in Sort Set in order Shine Standardize Sustain Total
10,3 Weeks) score score score score score score

1 1 1 2 1 1 6
2 1 1 3 2 3 10
3 2 3 4 3 5 17
4 4 3 6 7 9 29
352 5 6 3 7 8 9 33
6 8 6 8 8 9 39
7 11 8 10 9 9 47
8 13 9 10 10 10 52
9 13 10 12 10 10 55
10 13 12 12 10 10 57
11 12 9 9 8 9 47
12 12 8 8 8 8 44
13 11 8 7 7 7 40
14 6 6 7 7 7 33
15 6 7 7 6 7 33
16 6 7 6 6 7 32
17 6 7 6 6 6 31
18 9 10 9 9 8 45
19 10 11 9 10 8 48
20 10 12 9 12 9 52
21 12 13 10 13 9 57
22 15 14 14 14 9 66
Table 5. 23 15 14 15 14 10 68
5S weekly total scores 24 15 16 17 14 10 72

Scores
5S No Check point 0 1 2 3 4

Sort 1 Materials U
2 Instruments U
3 Connection apparatus U
4 Visual control U
5 Written standards U
Set in order 6 Quantity indicators U
7 Item indicators U
8 Location indicators U
9 Separation lines U
10 Connection apparatus U
Shine 11 Machines U
12 Floors U
13 Cleaning and control U
14 Cleaning responsibility U
15 Cleaning habit U
Standardize 16 Ventilation U
17 Lighting U
18 Working clothes U
19 Protection from dirt U
20 First 3S U
Sustain 21 Training U
22 Tools and parts U
Table 6. 23 Stock control U
5S audit check sheet 24 Activity boards U
form of week 4 25 Procedures U
 Residual Plots for Total Score The 5S lean
Normal Probability Plot Versus Fits technique
99 20

90
10

Residual
Percent

50 0

10 -10 353
1 -20
-30 -15 0 15 30 20 30 40 50 60
Residual Fied Value

Histogram Versus Order

20
4.8

10
3.6
Frequency

Residual

0
2.4

1.2 -10
Figure 1.
0.0 -20 Plots of residuals for
-20 -10 0 10 20 2 4 6 8 10 12 14 16 18 20 22 24
total score
Residual Observaon Order

Genetic programming (GP) is an irregular likelihood-based inquiry technique to assess

the ideal arrangement of any goal work. Holland (1975) suggests a genetic algorithm as a
program, which assesses the arrangement of the issue by a characteristic developmental
procedure in the mid-seventies. De Jong (1975) expands the calculation from the program
based on work-based and improvement of capacity-based enhancement start. The point
by point improvement of any numerical model with the assistance of GA was begun by
Goldberg (1989). GP is utilized to illuminate a scientific model in which a reaction was
influenced by many procedure parameters. The upper and lower limits of procedure
parameters were characterized during the announcement of the issue (Li et al., 2013;
Sharma et al. 2015). At first, one target work was set up for a maximization issue. At that
point, this capacity is unravelled by an alternate blend of transformation, traverse
capacity and determination. Relapse condition given by relapse examination was
additionally unravelled by utilizing GP. The lower and upper bound of weeks is 1–24
respectively.
Figure 2 shows the range of plot with the number of iterations. It was observed that the
range of residuals decreases with the increase in the number of iterations. Thus, the concrete
value of the score was obtained after 71 iterations. In this way, after the implantation of 5S
and with the increase of number of the weeks the total score increased as predicted by using
genetic algorithm.

8. Outcome of 5S
The 5S event was used to optimise workplace conditions in the manufacturing shop floor
facility. As a part of undertaking this event, changes were made to tool organisation, cleaning
schedules and other areas that needed better organisation.
The 5S event was kick-started with sorting. This phase resulted in the removal of items
that were no longer needed. This helped eliminate clutter and ensure that an untidy
workplace does not affect efficiency. Necessary items were stored where they could be
GS
10,3

354

Figure 2.
Range plot for
total score

accessed easily for the use which resulted in a reduction in floor space needed. Unnecessary
items were disposed of.
Sorting was followed by straightening. This stage helped organise the items to optimise
efficiency and flow. Every equipment placement was marked. Tools were colour coded and
placed on clamps. Nothing was to be placed on the floor. Frequently used parts were placed in
bins to enable easy access.
Sorting was followed by the third stage which is sweep or shine. The focus was placed on
keeping the workplace clean. Unwanted and unnecessary items were removed so that the
focus could be placed on other elements.
A 5S event can be quite rewarding by clearing cluttered workplaces and organising the
environment. However, if not maintained, the 5S event will be futile. This is where the fourth
stage comes in, which is standardisation. Through standardization, the best practices are
compared and agreed upon. Such practices are then followed throughout the organisation. Some
standards developed by the manufacturing facility were tools assignment and organisation,
placing tools on clamps instead of on the floor and immediate reporting of missing tools.
The fifth phase is sustained or control phase. The success of the 5S initiative depends
primarily on its maintenance. Assembly employees were responsible for conducting weekly
audits to point out activities which needed improvements. Results were put up on information
boards so that workers could be made aware of the improvements required in their
workstation.

9. Conclusion
It is easily known from the case study that lean manufacturing 5S is flexible. It can be easily
applied in all kinds of organizations. It focuses on eliminating waste and creating value in a
process. A small improvement in a firm can bring big changes to the firm. 5S are always
beneficial; they simply imitate the fact that the firm is now on the right track which in turn is
giving them the best profits. Benefits achieved from 5S events should never be doubted
because the success rate of the 5S application is too high. Both direct and indirect benefits are
achieved by implementing 5S events. We need to take 5S activities as a long-term thinking
process which should be employed by every person for the betterment of the company.
9.1 Managerial implications The 5S lean
The managerial implications are highly concerned with the relation between the employees technique
and the manager. Employees can help management and management can help employees to
improve productivity, improve performance and profitability by reducing manufacturing as
well as service cost. When there is no connection between the manager and the employee then
we find that workplaces face production of more waste, poor morale of workers which leads to
negative impression of workers on management and the situation gets worse where
employees may face termination of employment and the manager may face issues like 355
unionization.

9.2 Direction of work for future

By employing the techniques of regression analysis one can understand what the dependent
and independent variables in the organization are, for example, the demand in the market is
the independent variable; thus the stock or inventory we are storing is the dependent variable
as it solely depends upon the demand in the market. Regression analysis can help in studying
what factors in the organization culture help in better productivity of the workforce or other
assets. Regression analysis can help in motivating and providing incentives to the employees
and studying what incentives are bringing more change in the employee’s capabilities to
perform and shine better. The firms can use regression analysis to check the deviations where
the lag is coming and why the resources are not being used up to their best capabilities and
capacity. Thus, it can help to achieve the capabilities of the organization. At last, by
performing such regression analysis at all levels of the organization, sustainability can be felt
for the organization. Organization which is sustained has long-term prospects and growth
and thus reaches the heights in the market.

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Corresponding author
Shaman Gupta can be contacted at: shamangupta9@gmail.com

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