IMEG was hired by a leading industrial spring manufacturer to implement 5S methodology in creating an organized, efficient, and safe workplace by improving efficiency, safety, productivity, and quality.
THE PROBLEM
Unorganized Workspaces: Tools, materials, and equipment were not systematically arranged, causing inefficiencies.
Clutter and Waste: Excess inventory and unnecessary items occupied valuable workspace.
Lack of Standardization: No formal structure for maintaining cleanliness and organization.
Reduced Productivity: Employees spent excessive time searching for tools and materials.
lean engineering
THE PLAN
5S Audits:
Conducted comprehensive 5S audits using customer’s standard audit template.
Identified key problem areas affecting efficiency and safety.
Factory-Wide Zoning for 5S Implementation:
The entire factory was divided into approximately 35 zones.
Each zone was treated and audited as a separate 5S zone, ensuring a focused approach to workplace organization.
Red Tagging Event:
Launched a red tagging initiative to identify and remove unnecessary items.
Categorized materials based on their necessity and usability in the production process.
Visual Management Action Plan:
Developed a visual management system with clear labeling, floor markings, and standardized signage.
Ensured workspaces were visually structured for easy identification of tools, materials, and designated areas.
Action Register Development & Execution:
Created an action register to track problem-solving activities and assign responsibilities.
Implemented solutions for Sort, Set in Order, Shine, Standardize, and Sustain principles.
Continuous Improvement Plan:
Established a system for periodic 5S audits and ongoing activities to maintain improvements.
Implemented accountability measures to ensure long-term adherence to 5S practices.
Pilot Zone Implementation:
One zone was selected as a pilot where all 5S implementations were completed first.
This allowed stakeholders to review the effectiveness of 5S before scaling the process to the entire facility.
waste reduction
THE RESULTS
The 5S implementation led to:
Increased Workplace Organization: Clearly labeled and well-arranged tools and materials improved accessibility.
Clutter Reduction: The red tagging event eliminated unnecessary items, freeing up workspace.
Improved Productivity: Reduced search times and workplace inefficiencies led to faster operations.
Factory-Wide Standardization: Dividing the factory into 35 zones ensured a systematic and scalable 5S approach.
Sustained Improvements: A visual management action plan and periodic audits maintained the new standards.
Successful Pilot Implementation: Stakeholders reviewed and approved the pilot zone before full-scale rollout.
Through 5S audits, red tagging, zoning, visual management, and a pilot zone approach, IMEG successfully helped establish a clean, organized, and efficient workplace, setting the foundation for long-term operational excellence.
Ready to Eliminate Waste and Maximize Efficiency?
Contact us to streamline your operations and boost productivity—without sacrificing quality.
