WELCOME

4th CII National 5S Excellence

Awards 2019
11 October 2019
CHANDIGARH

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 DCJ GROUP
DCJ GROUP COMPANIES
AJAY POLY PVT. LTD
(Refrigerator Gaskets | Flexible
Magnetic Strips | Extrusion
Compounds)

AJAY INDUSTRIAL
POLYMERS PVT. LTD
Shri D.C. Jain Mr Rajeev Jain Mr Nitin Jain (DRIP IRRGATION SYSTEM)
(Group Founder) (Managing Director) (Director)
ENCRAFT INDIA PVT. LTD
DCJ GROUP (Thermoplastic Rigid Profiles, UPVC
Door Windows)

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DCJ GROUP
AJAY POLY PVT. LTD.
Ajay Poly Pvt Ltd Greater Noida
(Tool Room, Compound Soft, Extrusion, Ref. Door Gasket)
Ajay Poly Pvt Ltd Badarpur Delhi
(Tool Room, Compound Rigid, Extrusion, Ref. Door Gasket)
Ajay Poly Pvt Ltd Mohali
(Extrusion Gasket, Ref. Door Gasket)

Ajay Poly Pvt Ltd Sahajahanpur

(Extrusion, Gasket, ESO)

Ajay PolyDCJ
Pvt GROUP
Ltd Shirur
(Extrusion Gasket, Ref. Door Gasket)

Ajay Poly Pvt Ltd Shirwal (Satara)

(Extrusion Gasket, Ref. Door Gasket)

Ajay Poly Pvt Ltd Chennai

(Glass Tampering, Extrusion Gasket, Ref. Door Gasket)
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 COMPANY PROFILE
An Overview APPL is a division of DCJ Group ,it is started in the year 1991. APPL is one of the leading
manufacturers of Refrigerator Sealing Systems, it includes-Refrigerator Gaskets | Flexible
Magnetic Strips | Extrusion Compounds, Glass toughening & refrigerator glass shelf
Company manufactures entire range of -Refrigerator Door Gaskets, Refrigerator Door
Seals, Freezer Door Gaskets, Cooler Door Gaskets For Household, Glass shelf and
Commercial Refrigeration Applications (Visi-Cooler, Chest Freezer etc.)
8 plants in India, main plant in Noida.
Awards and Recognition
Products

Ready Door Gasket Spill Proof Magnetic ABS Decorative Thermoplastic Engineering
Glass Shelf strip Trim Specialist Rigid Profiles

Our Customers

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 Photograph of Company

Front-Side View Aerial View Back-Side View

Left-Side View Right-Side View Scrap Yard 3

 Photograph of Toilet

CEO TOILET OPERATOR TOILET

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 Shining Examples through Before & after
“5S” photographS

Before After

There is no housekeeping stand provide for Now there is housekeeping stand provide
PROBLEM housekeeping material. IMPROVED for housekeeping material.

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 Shining Examples through Before & after
“5S” photographS

Before After

Lab instrument kept in haphazard Proper marking of things on table.

PROBLEM manner . IMPROVED

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 Shining Examples through Before & after
“5S” photographS

Before After

•No colour identification done on die. Now colour identification done on die as
PROBLEM IMPROVED per customer.

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 Shining Examples through Before & after
“5S” photographS

Before After

•Toilet in bad condition •Now toilet tiles and all accessories

PROBLEM IMPROVED changed.

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 Shining Examples through Before & after
“5S” photographS

Before After

Samples are not arranged properly. Now all samples arranged properly and
PROBLEM IMPROVED model wise.

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 Shining Examples through Before & after
“5S” photographS

Before After

•Kaizen Gallery not properly maintain. •Now Kaizen gallery maintained properly.
PROBLEM IMPROVED

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 Shining Examples through Before & after
“5S” photographS

Before After

File are not kept properly in cabinet and Now all files are kept properly with description
and green labels. Green lines are given to all files.
PROBLEM there is no any description label attached. IMPROVED If any file is missing the green lines break.

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 Shining Examples through Before & after
“5S” photographS

Before After

PROBLEM IMPROVED

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 Shining Examples through Before & after
“5S” photographS

Before After

PROBLEM IMPROVED

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 Shining Examples through Before & after
“5S” photographS

Before After

PROBLEM IMPROVED

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 Examples of Visuals

• SHADOW BOARD IMPLEMENTATION

Shadow Board is implemented in plant. 3

Examples of Visuals

MACHINE DISPLAY BOARD

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 Examples of Visuals

Before After

Board not displayed

•World class quality board not •Now world class quality board displayed in
PROBLEM displayed in plant. IMPROVED plant & maintained on daily basis.

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 Examples of Visuals
Before After

There is no safety calendar in shop floor. Now safety calendar available in plant .
PROBLEM IMPROVED

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Examples of Visuals

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Examples of Visuals

EHS GALLERY

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 Examples of Visuals

Before After

FIRE EXTINGISHERS PLACED ON WALLS NOW FIRE EXTINGUSHERS HIGHLIGHTED

PROBLEM NORMALLY IMPROVED WITH ZEBRA LINES

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 Examples of Visuals

•We also displayed die colour coding board in plant.

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 Examples of Visuals

Before After

Board not displayed

•No FIFO system boards are displayed. •Now we displayed FIFO System Boards.
PROBLEM IMPROVED

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 Examples of Visuals

STANDARD FOR SELF-CHECK

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 Examples of Visuals
Safety Dos and Don'ts Board to be incorporated in the Factory

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 5S manual

Please Double Click to open 6S

Procedure

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Organization structure
for 5S

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5S vision statement and
objectives

5S COMMITMENT
We are committed to practice the culture of
5S towards achieving the target to be the
No. 1 waste management company in the
world.

5S POLICY
1. To have a safe, clean and well
organized work place.
2. To have high quality of works, services
and high operational activities among
workers.
3. To internalize 5S work Culture.

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 Waste disposal procedures

 No segregation of waste  Segregation of waste

 No record of waste generation  Record of waste generated
 No fixed disposal frequency  Fixed waste disposal frequency
 No control on waste  Controlled waste management

What you can not measure can not control

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 Waste disposal procedures

Collection, Segregation, Storage & Disposal Mechanism

Extrusion
process Process Waste Management
rejection

Gasket cutter
offcuts Send back to
Segregation Store APPL,noida for usage
OS&D
AMIC in other Applications
offcuts

Line rejection

Packaging Waste Management

Corrugation waste

Sell to
Plastic
Segregation WMC authorized
waste
Recycler

Garbage

0 Waste to landfill 3
THANK YOU
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