LEAN MANAGEMENT

ASSIGNMENT-2

Topic:- Implementation of Lean Tool in Manufacturing Setup

Submitted To:- Mr. Nand Kishor Barik Sir

Submitted By:- Abhiyanshi Tikarya (BFT/21/683)

Mohamed Niyas KV (BFT/21/929)

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Acknowledgment

First and foremost, I, Abhiyanshi Tikarya am highly grateful to NIFT for providing me with
an opportunity to do this assignment on “LEAN MANAGEMENT”.
I would like to express my deepest thanks to my mentor and faculty Mr. Nand Kishor sir for
his exemplary guidance, monitoring and constant encouragement throughout the project and
also for providing valuable insights of the project as well as my work and for mentoring me
at each and every stage, leading to the successful completion of my project.

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Table of Contents
Acknowledgment...............................................................................................................2
5S Lean Tool......................................................................................................................4
5S Policy............................................................................................................................5
Why need 5s in Garments industry?...................................................................................7
Traditional Manufacturing vs. 5S Lean Manufacturing.....................................................8
FIVE CORE PRINCIPLES OF LEAN MANUFACTURING:-..........................................9
7 COMMON WASTES.....................................................................................................10
LEAN MANUFACTURING BENEFITS.........................................................................10
AVAILABILITY OF 5S IN THE GARMENT INDUSTRY...............................................11
ACTIONS REQUIRED FOR THE GARMENTS INDUSTRY TO IMPLEMENT 5S.......12
CONCLUSION................................................................................................................15
REFERENCES...............................................................................................................16

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5S Lean Tool
5S comes from 5 Japanese words and each of them starts with S.
These are:-
Seiri-Sort, Seiton-Set in order, Seiso-Shine, Seiketsu-Standardize, and Shitsuke-Sustain.
are the results of translating these five Japanese terms into English. 5S is a fundamental
component of Lean Manufacturing, a method used in the apparel industry to create a neat,
orderly, and aesthetically pleasing work environment. That's the reason why the apparel
industry has to adopt 5S.

The 5S method aims to improve workplace organization through productive and well-
managed output. In addition to finding and getting rid of trash, it is also utilized to work with
better techniques that engage several teams in the process. We focused on the enactment in
the Garment Construction Laboratory in this study. First, the laboratory's instruments and
equipment were categorized and recognized based on their needs. Afterwards, they were
placed in a methodical order, and standard operating procedures were made for each step
while taking industry standards and safety into account.

In order to increase production and competitiveness, 5s management practices are being used
in every firm. The primary goal of 5s is to provide a neat and orderly workspace across the
whole workplace. The use of 5S in the educational sector will boost a better working
environment, reduce workplace accidents, and improve the workplace. This report will aid in
the identification and knowledge of wastes as well as give strategies for their removal and
management within the organization, hence promoting better organized work practices within
the college.

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5S Policy

The 5s method is used to establish an organized organizational culture. It serves as lean

manufacturing's fundamental cornerstone. The 5s is a Japanese management methodology.
This method focuses on developing standard operating procedures, fostering a quality
atmosphere inside the company, and ongoing organizational improvement.

5s is the acronym of five Japanese words

 Seiri – Sort
 Seiton – Set in Order
 Seiso – Shine
 Seiketsu – Standardize
 Shitsuke – Sustain

1S: Sort: Clearly distinguish needed items from unneeded and eliminate.

2S: Set in order: Keep needed items in the correct place to allow for easy and immediate
retrieval.

3S: Shine: Keep the workplace neat and clean.

4S: Standardize: The method by which Sort, Set in order, Shine are made habitual.

5S: Sustain: Maintain established procedures.

Additional S: Safety – Strive to eliminate the accident in the workplace.

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Sorting is where Seiri 5S begins. Sorting is the process of separating undesirable things using
all tools, machinery, and equipment. Establish daily, weekly, and monthly goals and maintain
them apart. Defective, useless, and sometimes used items in your business have to be
specified as well.

Keep track of the items that you no longer require that are thrown away, both new and pre-
made. Numerous items are randomly stored in each area of clothes. Thus, with relation to
them, the first.

Seiton It matters the order you place the 5S in. Every item, section, and region (In, Exist)
needs to be labeled correctly and kept neatly structured. Items from the two categories
shouldn't be combined or hidden in one area. Stairwells, separation lines, and passage
markers are all neatly and clearly designated in accordance with requirements. Ensure that,
during business hours, the exit is both unlocked and accessible. Check to make sure exit
doors don't have lever-style (one-handed, one-move door openers) or panic hardware, if
applicable. You can quickly locate and collect all of your business supplies as needed by
keeping them organized in your clothes shop. As a result, every material needs to be kept in
the prescribed sequence in storage.

Shine, the third Sesiso in the 5S, literally translates to "cleanliness." Every item/workspace
Everything that has to be maintained clean includes the floors, walls, stairs, ceilings, pipes,
shelves, cabinets, shelving, machinery, storage, supplies, and lights. Simple access to all
cleaning supplies and equipment. A cleaning schedule is established, and then a checklist is
attached on a board that is easily seen. To keep pests at bay, practice routine pest
management. In addition to being a matter of compliance, cleanliness promotes a healthy
work environment in offices and clothing manufacturers.

Seiketsu It stands for "standardized clean-up." The reason for this is a single, orderly action
that left the workplace "shiny clean" and raised the bar for hygiene. Meeting this criteria is
made feasible and practicable by seiketsu. The secret to applying 5S in the workplace is to
follow the first three stages. This part covers the process of maintaining the first three S's as
well as visualization using information displays, related SOPs, signage, color codes, and
other markers placed around the plant. Five recurring checks should be made against the
checklist, rate each area, and publish. If formal training is required, keep training records for
improvement. These standardizations will improve operational efficiency in the apparel
industry.

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It is a process that involves more than just locating and eliminating waste; it also involves
enhancing the organization's safety, fostering a quality environment, and raising productivity
levels in businesses and educational institutions. The student will benefit from it in the future
as, after finishing their education, they will find it easy to adjust to the 5s method in the
workplace.

Why need 5s in Garments industry?

The 5S methodology is a systematic approach to workplace organization and productivity
that originated in Japan. The 5S principles include Sort, Set in Order, Shine, Standardize, and
Sustain. The principles are applicable to any industry, including the garments industry. In this
article, we will explore why the 5S methodology is necessary in the garments industry, and
how it can improve the efficiency and productivity of the industry.

1. Safety One of the main reasons why the garments industry needs the 5S methodology
is safety. The industry involves the use of many different machines and tools, which
can pose safety hazards if not organized and maintained correctly. The 5S
methodology helps to eliminate safety hazards by ensuring that tools and equipment
are properly stored, labelled, and easily accessible.
2. Efficiency The 5S methodology helps to improve efficiency in the garments industry
by eliminating waste and streamlining processes. For example, by organizing the
workplace, workers can spend less time looking for tools and equipment, and more
time on productive tasks. By reducing the time spent on non-value-added activities,
workers can complete tasks more efficiently, which leads to increased productivity.
3. Quality In the garments industry, quality is crucial. The 5S methodology can help to
improve quality by ensuring that all tools and equipment are properly maintained and
calibrated. By having a standard procedure for maintenance and calibration, workers
can ensure that the quality of the finished product is consistent.

4. Inventory Control The 5S methodology can help to improve inventory control in the
garments industry by ensuring that all materials are properly labelled and stored. By
having a clear labelling system, workers can quickly identify the materials they need,
and prevent mistakes that can lead to waste or delays.
5. Employee Morale The 5S methodology can also have a positive impact on employee
morale. By organizing the workplace and creating a clean and safe environment,
workers feel more comfortable and are more motivated to work. The methodology
also encourages teamwork, as all workers are responsible for maintaining the
workplace.
6. Cost Savings The 5S methodology can help to reduce costs in the garments industry
by eliminating waste and improving efficiency. By reducing the time spent on non-
value-added activities, workers can complete tasks more efficiently, which leads to
increased productivity. Additionally, by properly maintaining equipment and tools,
the need for repairs and replacements is reduced, which leads to cost savings.

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The 5S methodology is a powerful tool for improving the efficiency, productivity, and safety
of the garments industry. By implementing the 5S principles, the industry can reduce waste,
improve quality, and reduce costs. Additionally, the methodology can have a positive impact
on employee morale, leading to a more productive and efficient workforce. Overall, the 5S
methodology is a critical tool for any garments industry looking to improve its operations and
remain competitive in today's global marketplace.

Traditional Manufacturing vs. 5S Lean Manufacturing

FIVE CORE PRINCIPLES OF LEAN MANUFACTURING:-

 Value: Value is based on the customer's willingness to pay and is assessed from their
point of view when it comes to goods or services. The manufacturer or service
provider then creates this value by trying to reduce waste and expenses in order to
meet the best pricing for the client and increase revenues.
 Map the Value Stream: This concept entails examining the supplies and additional
resources needed to create a good or service in order to find inefficiencies and
opportunities for improvement. The value stream encompasses a product's whole
lifespan, from raw materials to disposal. Waste must be found at every level of the
manufacturing cycle, and everything that doesn't contribute value must be eliminated.
To accomplish this phase, chain alignment is frequently suggested.
 Create Flow: Improving lead times by eliminating functional obstacles is the goal of
creating flow. This guarantees that procedures go without hiccups and may be
completed with little wasted time. In order to provide a steady stream of production or
service delivery, flow must be established. Disrupted and discordant manufacturing
processes are costly.

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  Create a Pull System: Under a pull system, work is done only when there is a
demand. Push systems, which are employed in manufacturing resource planning
(MRP) systems, are the antithesis of this. With output adjusted to match these sales or
production projections, push systems calculate inventories ahead of time. However,
this can lead to either too much or too little of a product being produced to fulfil
demand because many projections are inaccurate. This may result in higher storage
expenses, thrown off deadlines, or worse customer satisfaction. Pull systems depend
on adaptability, communication, and effective procedures to function well and only
operate when there is demand. Teams using the pull approach may only go on to new
assignments when the preceding procedures have been completed, allowing the team
to adapt to challenges as they arise in the knowledge that the prior work is mostly still
applicable to delivering the product or service.

 Perfection: Kiichiro Toyoda, the founder of Toyota Motor Corporation, coined the
term "Kaizen," which refers to the pursuit of perfection via ongoing process
improvements (see "When and Who Invented Lean Manufacturing?" above).
Continuous process evaluation and improvement is necessary for lean manufacturing
in order to continuously remove waste and identify the ideal solution for the value
stream. Metrics like lead times, production cycles, throughput, and cumulative flow
must be measured in order for the concept of continuous improvement to have a
significant and long-lasting impact on an organization.

7 COMMON WASTES
• Over-Production
• Inventory
• Transportation
• Defects
• Motion
• Extra Processing
• Waiting
• Under-Utilized Human Resources

5S LEAN TOOLS BENEFITS

Lean project management requires reducing or eliminating waste, however depending on who
is questioned, lean manufacturing offers varying advantages. While some claim it is boosting
business profits, others insist that the modifications are made only to provide value for
customers and raise their level of pleasure. Here are some shared objectives.

 Improve Quality: To stay competitive, companies can’t be complacent, but must

meet customers’ changing wants and needs. Therefore, processes must be designed to
meet their expectations and requirements. Adopting total quality management can
make quality improvement a priority.

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  Inventory Management: Thanks to the just-in-time production method, lean
manufacturing reduces excess inventory, which reduces costs and prevents production
issues.
 Process Improvement: Lean production systems are always being improved, thanks
to the “continuous improvement” lean principle. Value stream mapping it’s essential
for this.
 Eliminate Waste: Waste is bad for costs, deadlines and resources. It takes without
adding any value to a product or service. By eliminating waste, a lean manufacturing
system can produce better products, at lower costs.
 Reduce Time: Time is money, as the adage goes, and wasting time is therefore
wasting money. This is especially true for the manufacturing industry. Reducing the
time it takes to start and finish a project is going to create value by adding
efficiencies. Learn and apply some time management strategies.
 Reduce Total Costs: Money is saved when a company is not wasting time, materials
and personnel on unnecessary activities. Overproduction also adds to storage and
warehousing costs. Understanding the triple constraint is the first step to
understanding cost management.

AVAILABILITY OF 5S IN THE GARMENT INDUSTRY

Following 5S best practices in the textile and clothing sector will provide you with the
following advantages:
 Health and safety are guaranteed
 the fundamentals of implementing quality improvement are covered; productivity is
increased
 time, money, and storage space are saved; accidents and errors are minimized
 efficiency is increased; the first steps of lean practice are taken; customer satisfaction
is improved
 storage time is decreased; downtime and waste are reduced; a positive work
environment is created
 visualization and labelling are used
 corporate image is enhanced
 and the workplace is optimized in accordance with needs.
 Everyone is aware of their work duties, including the where and when;
 Housekeeping is disciplined

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ACTIONS REQUIRED FOR THE GARMENTS INDUSTRY TO
IMPLEMENT 5S
 Grab a "before" picture.
 Verify that the first three S are applied appropriately.
 All checklists and documentation related to team activities have to be posted on the
5S board.
 Make it a regular and accepted practice to repeat the first three Ss in a methodical and
regular manner.
 Standardize holding area regulations and red tag processes. Establish a method for
maintaining housekeeping.
 Establish a timetable for tidying your workspace. Assigning this to a cross-functional
team is a typical method.
 One effective strategy for sustaining and boosting interest in 5S is inter-sectoral
rivalry..
 Assign workers to the machine and work area. There will be ongoing, dedicated team
inspections/audits and assessments (including senior personnel).
 Highlight excellent performance and best practices rather than criticizing poor
examples.
 Take a picture "after" and share it on the 5S board. Reward the highest scoring

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CONCLUSION
The use of lean manufacturing has become a crucial strategy for reducing expenses. By
incorporating less human labour, inventory, product development time, and space, lean
manufacturing aims to produce high-quality goods in the most economical and efficient
manner while also reducing all forms of waste and non-value-added activity. This allows the
company to become highly responsive to customer demand. Any improvement initiative that
seeks to remove waste from the manufacturing process and, ultimately, increase a
company's bottom line production by improving goods and services and reducing expenses
should start with the 5S system. A "5S" workplace has been adopted by several
manufacturing facilities, ranging in size from small firms to huge corporations, as part of
Continuous Improvement or Lean Manufacturing procedures organizational and
housekeeping methodology to reduce waste and improve quality. More established
fabrication offices find this notion especially interesting since it allows them to focus on their
primary problem without having to make a financial investment. By successfully
implementing the 5S model, one such industry, machine tools, was able to boost
productivity and uncover a rise in profits. Other benefits of applying the 5S model included
improved worker excitement and punctuality as well as safer working environments. The 5S
board must educate every employee about the idea through training and mindfulness
programs, and continuous improvement actions are anticipated to improve creativity and
reduce waste.

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REFERENCES
 https://www.ijsdr.org/papers/IJSDR2309180.pdf?ssp=1&setlang=en-
IN&safesearch=moderate
 https://ordnur.com/textile/implementation-of-5s-in-apparel-industry/
 https://textilelearner.net/5s-methodology-in-textile-and-garment-industry/

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