Mission:

Improve quality of products and customer

satisfaction through 5S, Lean and TPM.

5S
1S-Sort-Seiri

SORT means we remove all items from the workplace that are
not needed. And keep the needed items in a classified
manner.

2S-Set in Order-Seiton
A place for everything and everything in its place

3S-Shine Sort-Seiso

SHINE means regular cleaning with inspection

It also means preventive maintenance

4S-Standardize-Seiketsu

Standardize means that you need to have some standards in

place to make sure that everything is kept where it's
supposed to.

5S-Sustain-Shitsuke
SUSTAIN is isnt a single separate activity. We SUSTAIN the
continual improvement habits developed during first 4Ss
implementation.
5S
5S
5S
5S
5S

Seiri;
Seiton;
Seiso;
Seiketsu;
Shitsuke;

Sort, Clearing, Classify

Straighten, Simplify, Set in order, Configure
Sweep, shine, Scrub, Clean and Check
Standardize, stabilize, Conformity
Sustain, self-discipline, custom and practice

Steps:
1. Arranging 5S awareness program (Training)
2. Formation of 5S steering committee
3. Formation of department wise 5S implementation team(Coordinator
and members)
4. Training of Internal auditors.
5. Preparation of Internal audit check sheet
6. Starting of monthly Internal Audit

7. Quarterly completion on 5S themes.

TPM:

Continuous improvementWhat: Eliminate Breakdowns, Defects and any other type of loss to
achieve Production effectiveness
How: Using the standard 10 step Approach
AUTONOMOUS MAINTENANCEWhat: Develop Equipment competent Workforce empowering to look after
their own equipment
How: Executing the 7 Steps of Autonomous Maintenance
Planned maintenanceWhat: Improve the effectiveness of the Maintenance Department so that
the 8 Big Losses are no Longer generated
How: Do failure analysis, Develop Standard Maintenance Practices and
Have routines in place
Quality maintenanceWhat: Achieve ZERO Quality defects by Sustaining Correct equipment
conditions
How: Establishing 4 M conditions and connect the Equipment parts to
Defects Generated.
Involves AM, PM and E&T

Capability developmentWhat: Boost the expertise of the Operators and the Maintenance team
How: Generating and imparting training as per the Skill gap through
SPL, OJT, Specialized Training courses
Safety & EnvironmentWhat: Achieve and Sustain ZERO Accidents
How: Creating a healthy rewarding and Pleasant work places
Early equipment managementWhat: Reduce Product and Equipment development Lead times and achieve
stable Commissioning of new products and equipment thus having a
VERTICAL START-UP
How: Eliminating flaws at the design stage and carrying out design
reviews
Office TPMCreate Highly Efficient Offices and thereby Provide Support to the
Production Department

Lean Management:
Lean is about creating the most value for the customer while
minimizing resources, time, energy and effort. A lean approach to work
is about:

Understanding whats really going on at the place where value is

created commonly known as the gemba.

Improving the processes

created and delivered.

Developing
coaching.

and

empowering

by

which

people

products
through

and

problem

services

are

solving

and

Developing leaders and an effective management system.

The original seven Types of waste are: TIMWOOD

Transport (moving products that are not actually required to

perform the processing)

Inventory (all components, work in process, and finished product

not being processed)

Motion (people or equipment moving or walking more than is

required to perform the processing)

Waiting (waiting for the next production step, interruptions of

production during shift change)

Overproduction (production ahead of demand)

Over Processing (resulting from poor tool or product design

creating activity)

Defects (the effort involved in inspecting for and fixing

defects)

And Now 8 Waste

DOWNTIME
D: Defects
O: Overproduction
W: Waiting
N: Non Utilization of Talent
T: Transport
I: Inventory
M: Motion
E: Extra Processing