Assessment of 5S as a Tool to Reduce Non-value Adding Operational Time:
A Case Study.
Abstract
‘Waiting’ and ‘Motion’ are two wastes of the seven wastes considered in
the lean manufacturing concept. They both consume valuable operating
time and slow down the production cycle. The main goal of this paper is
to incorporate 5S, a lean manufacturing method with a view to reducing
these two wastes. 5S was implemented to develop a system of organization
for blowing Sizers and printing blocks in the work area. 5S derived from
five Japanese words, when translated, mean sort, set in order, shine,
standardize, and sustain. Research has been carried out in a poly bag
manufacturing industry in Bangladesh with the goal of increasing
productivity by minimizing non-value - added operational time. The
manufacturing of poly bags consists mainly of 3 operations; blowing,
printing and sealing. Following the implementation of 5S in these areas,
the lead time for blowing operation decreased by 8% and the lead time
for printing operation decreased by 18%. The assessment was
successfully conducted and established in this study. A scope for
improvement has been opened through this research, which may inspire
other researchers to consider implementing the 5S tool in their
respective research areas as a tool to reduce non-value - added
operational time.