Introduction to 5S -The Super Organiser

5S Structure

 

Introduction to 5S – Super Organiser

The 5 steps of 5S – Super Organiser are as explained below:

Sort:

This process identifies the items that are required to perform work in the work areas. Clear (sort out) all other items from the work area. It has following benefits:

  • Efficient use of work space
  • Improved safety
  • Improved productivity
  • Improved utilization of materials, supplies, and resource
  • More visible work flow
  • Improved employee satisfaction
  • Improved quality

Set In Order:

Aplace for everything & every person at its place. This supports in ease for retrieval. It has following benefits:

  • Elimination of 7 wastes and ease effort needed to search for or retrieve tools and supplies.
  • Easy identification of any missing tools
  • Improved safety through an organized workplace
  • Increased productivity

Shine:

Proactive/preventive housekeeping to keep work areas, work surfaces, and equipment clean and free from dirt, debris, oil, etc. Benefits:

  • Cleaner and more satisfying place to work
  • Improved Quality standards
  • Maintenance issues exposed faster (planned downtime vs. unplanned downtime)
  • Improved safety (fewer accidents)
  • Improved work culture

Standardize:

Do things in a consistent and standard way. Formulate standardize procedures for activities, instruction, schedules, checklist for helping keep the workplace clean and organized. Standardize work area layouts and storage techniques wherever possible. Visual Management implementation for ease of maintaining standardisation.

Sustain:

Integrate 5S principles into the organization’s objectives in order to sustain new standards and continually improve the workplace.

Workshop on 5S

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Case Study – Frequent maintenance in Stack Analyser (Banish MUDA)

Case Study – Frequent maintenance in Stack Analyser (Banish MUDA)

This is a beautiful case study resembling positive approach of the team towards finding solution.

A stack analyser was having very high frequency of maintenance. Being mounted in stack of incineration plant, the probe was exposed to dust & acidic gases, which were the main cause of probe failure.  Main Issues with the Analyser is:

  • High Frequency of Cell and heater failure.
  • Frequent chocking of cell assembly.
  • High time required for cleaning and cell replacement.
  • High cost of maintenance

The team took up the challenge to come out of the issue. The study done was a good example of usage of various reliability tools like RCA, Fishbone diagram, Brainstorming, etc. ,there is another angle to it, ie. Lean Management. The main objective of the study was to reduce the quantity of jobs performed on the analyser.

The team has recently gone through “7 Wastes-Mr. TIMWOOD “. They decided to identify the wastes in the activities on the analyser. All the activities were identified & written.

Each activity was studied and type wastes were identified.

Case Study- Frequent maintenance in Stack Analyser (Banish MUDA)

Analysis of the identified waste is as under:

  1. Transportation of probe to the repair location: Can the probe be repaired at the installed location?
  2. Motion of the workmen for steaming, hammering & temporarily electrical connections: Why Steaming, Hammering is required? Why temporarily connections are required?
  3. Defect during leak checking: What is the procedure for ensuring correct assembly?
  4. Inventory: How to reduce inventory required supporting the frequent maintenance?
  5. Waiting: Why can’t the warm up done at location?
  6. Over Processing: Why calibration & response check is required two times?

The next step was to find answer to these questions. The maximum time was consumed by removal of Cell & seal assembly. RCA tool, Why Why analysis was used to drill down to accumulation of the acidic dust at the cell as the root cause. A ceramic diffuser was prepared with OEM, to put in place of mesh, which is more capable of filtering dust. This small change after value engineering has resulted in substantial improvement in terms of time, cost, inventory, maintenance frequency, reliability & availability of the instrument.

Continuous Improvement

Cost of Modification: Rs. 25000

  • Total time of job was reduced from 8.8 hours to 4.3 hours.
  • No. of jobs reduced from 10/year to 4/year.
  • Material cost reduced from Rs. 1.8 Lakh to Zero.

Continuous Improvement

Experience of industries has been concentrated in different quality, Reliability & Lean tools. Correct knowledge & implementation of these tools is necessary for best results.

Check other case studies on Vanilla Ice Cream and Flight 5390 failure.
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Case Study- Frequent maintenance in Stack Analyser (Lean Tools)

Fault Tree Analysis (FTA)

FTA is fault tree analysis, used for identifying causes required for a particular fault/event to take place.

This technique uses basic symbols of electronic & logic field. The Fundamental symbol used are AND & OR gate.

Truth table for AND & OR gates:

Input Output
A B AND OR
0 0 0 0
0 1 0 1
1 0 0 1
1 1 1 1

Symbols of AND & OR gates:

and or gates

The failure mode being studied is called head event.

The basic concept of this technique is to put all effecting events in a logical form.  Take a case of motor stoppage. The motor can be stopped due to following reasons:

  1. Power loss
  2. Overload
  3. Coil Damage
  4. Process interlock operated

Further power loss can occur if the incomer power supply fails & the emergency generator also fails at the same time. Over load can occur due to chocking in pipe line, or, the isolation valve is closed. Coil can damage due to over current or moisture ingress. Process interlock can be operated due to instrument malfunction or real high vibration.

The Logic tree can be built as follows:FTA

All the identified events can be given probability of failure depending upon MTBF calculated from past events. In case both events are required for resultant event to occur ie. AND gate, the probabilities are multiplied. In case, any one input can have the resultant impact ie. OR gate probabilities are added.

The FTA Analysis is done for finding out all probable faults possible. This enables us to attack on right cause for identify & eliminating the fault.

check some of these interesting posts of time management and of super organiser as well.
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