Post on 12-Sep-2019
1 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Case Study – 1S, 2S, 3S System Deployment
1. Introduction of the Project.
Background & Context:
1,2S,3S system form the basis of any Lean project .As per the findings from diagnostic study company is
following completely Traditional Practices. To start any lean deployment 1S, 2S & 3S are of utmost
importance. To train & create awareness about 5S & Lean practices among team is very necessary.
Reasons for the selection of project:
1. Sorting between Wanted and unwanted material – Material scattered all over the work
place
2. To have a Lean Layout reducing waste – Space Optimization
3. To improve Team Morale
4. To improve cleanliness level of the factory
Project Team:
1. Mr. Bharat Sheth – CEO
2. Mrs. Manjusha Sheth – Proprietor
3. Mr. Vinod
4. Mr. Ashok Bhosale
Project Schedule: month wise activities in this phase
Sr No Month Activity Remarks
1 16/02/2015 Training on:
1.Current and future state
mapping
2. Spaghetti Chart.
A full day workshop conducted.
Training for spaghetti (current and
future State) charting done.
Accordingly respective teams mapped
current and future state layouts.
During the future state layout mapping
the main objective was to reduce
transportation and motion wastes.
Space Optimization was main motive
during the activity
Cluster: SAAP Location: Satara Status as on 27/04/2015
Name of the
SPV/DPG
Manufacturer’s
Association of
Satara
Name of the Unit Bharat Enterprise
Name and contact details
(including address, phone
and email)
B-17/2,Old M.I.D.C, Satara
Cell : 9422038307;
eMail : bharat.sheth@rediffmail.com
Location of
SPV/DPG
MAS Bhavan,
P-76, Additional M
I D C,
Satara 415 004.
Name & Address of the
Consultant
Solutions Kaizen Management Systems
LMC Minish Umrani
B-1/2, Suvidha Dnyanganga,
Jadhavnagar, Vadgaon Bk., Pune 411041.
Cell 9822390363,
eMail : minishumrani@gmail.com
Date of Appointment of
Consultant 17 November, 2014
2 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Sr No Month Activity Remarks
2 02/03/15 &
03/03/15
1S Kaizen Blast Blast of 2 days was scheduled .There
was no production plan for these 2
days.
5S and motivational training was given
to all staff and workers.
Red tagging activity was done by
team. Immediate decisions work taken
by management. Cleaning of the
areas was done by respected teams.
Further mechanical and electrical
repairing activity work carried over the
month.
3 15th March To
30 April 2015
Future State Layout deployment As per the future layout finalized on
paper the deployment was started
Related Civil and fabrication work was
completed.
Total free space available after new
layout deployment: 992 Sq.Ft.
4 May 2015 Fine tuning of the new Layout
deployed.
Layout markings and Visual locators for
the place.
2. Process description & Measurement Plan : N.A
3. Situational Analysis
Approach used for analysis of process performance
Spaghetti charting – This important tool of lean was used to study the transportation and motion
wastes in the current layout
Point wise description of observations made after analysis with the help of graphs & charts /
snaps/videos:
1. Huge transportation of material – redundant movements
2. No specific area for storing Raw Material & FG
3. Material scattered over the work place
4. Net Weaving activity carried outside Factory area due to lack of space.
5. Fatigue caused to workers due to heavy material movements.
6. Productivity loss due to transportation & motion wastes.
3 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
PHOTOGRAPHS:
Current Spaghetti Chart Future State Spaghetti Chart
Team Mapping Spaghetti Chart Project Team
4 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
4. Improvement Plan
Sr
No Activity Description Responsible
End Date
1 Change Location of Water Tank Mr. Vinod
2 New Hopper Fitment Mr. Bharat
3 Electrical Wiring Mr. Bharat 27/04/15
4 Plastering of the Finished Goods area
Mr. Bharat
5 Outer area Flooring to be done Mr. Bharat
6 Shifting of the RLM2, 3 & 4. Mr. Bhosale 02/05/15
7 Shifting of Re Coiling Machine Mr. Bhosale 10/03/15
8 Shifting of Raw Material Godown
to mezzanine floor
Mr. vinod 16/03/15
9 Starting of Extrusion No 2 machine
with new water tank
Mr.Bhosale 10/04/15
10 Cleaning Factory outside area &
Shifting net weaving activity inside
Production Area
Mr.Bhosale 8/04/15
11 Trees & Vegetable Plantations Mrs. Manjusha 04/03/15
5 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Before & After Photographs:
Project Team:
Factory Surrounding Area:
Before After
Company surrounded by grass – Shabby looks Area Cleaned – Fencing done. Vegetable
plantations done
6 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Before After
Grass grown – Company entrance area Area is cleaned & vegetable plantations
are done
Before After
Material Stacked since years – No traceability Area cleaned – Scrap removed & used for
storage before dispatch
7 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Before After
Net Weaving Activity carried out at the entrance of Space Created in the Production Area for net
Factory – Outside Production Area Weaving activity. So entrance of company is
clean & presentable
Before After
Finished Goods Storage – No Fixed Locations Size wise dedicated Locations created for FG
stock Storage
8 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Production Area:
Before
Material & machines scattered over the area. No fixed locations. Lot of space wasted.
After
Space Optimized By changing the machines positions & fixing spool/ bobbin Areas.
9 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Before After
Rope Machine Area – Machines scattered Separate Location created for rope machines.
This area now used for net weaving activity
which was initially carried outside the Factory
Before After
Mezzanine Floor area covered with Area Cleaned – Used for Raw Material Storage
Un used gunny bags
10 Satara Agriculture & Allied Process Cluster 1 – LMC – Mr. Minish Umrani, CEO, Solutions KMS
Before After
Tube Lights Hanging with help of Ropes Wiring done & arrangements for bulbs & tube
Lights done
Conclusion:
1. Total space saved after optimization is 992 sq ft.
2. Dedicated places created for everything – raw material/ finished goods / machinery.
3. Material handling equipment like trolleys used. This reduced fatigue of workers.
4. Transportation –Reduced as most of the storage done at point of use
5. Net Weaving Activity which was carried outside Production Area – Entrance of Factory due
to lack of space is now done in the Production area Space is created.
6. Outside Factory area cleaned & tress & vegetable plantations done – Improved look of the
Factory.
7. Electrical Wiring &Fittings changed – Improved safety & look of the work place.
Financial Savings:
Earnings from Scrap: RS.70000/-
5. Standardization of the activities
No necessity of SOPs found for this Project.
Remarks by LMC: