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: