After detailed study on the existing situation, the project work concerns troubleshooting the problem that directly and indirectly interrupts the production. The burning issue was tracked in the fabric stores department which forms the base of firm. Because in the fabric stores there was higher delay and waiting time during fabric issual either sampling or bulk fabric. This was due unorganized storage area, no summoning system and inefficient and insufficient manpower.
Thus implementation of 5S system was must so as to acquire effective workplace organization and standardized work procedure. The 5S simplifies the work environment reducing the wastages and non value adding activities.
The project title being 'Streamlining and Re-engineering of Raw material stores by Implementing 5S System'. The objectives are to streamline the whole process flow and thus minimizing the unnecessary wastage of time and to implement the 5S housekeeping system. The 5S implementation was further divided into two stages as re-engineering of layout and bin card implementation. The layout was re-engineered by sorting the material buyer-wise and style-wise. Also the quantity of material per pallet was standardized. Bin card was implemented for the ease of identification of material.
The methods used for the analysis of the current situation are:
1. Cause and effect analysis
2. Failure mode effect analysis
After the development and approvals of the mitigation suggestions, the implementation part began. Maximum suggestions have been implemented, with some of them under partial implementation.
The authors are associated with Centre for textile functions (CTF), NMIMS MPSTME Shirpur campus, shirpur Dist- Dhule, Maharashtra.