Implementation of 5S and spl at Hitesh Mechanical Pvt. Ltd.

Abstract

The objective of this thesis is to improve the facility layout of manufacturing firm using Systematic Plant Layout (SPL) or Systematic Layout Planning (SLP) and implementation of 5S. This project is conducted at HITESH MECHANICAL PVT. LTD, RABALE where various pressure vessels, agitated vessels, chemical reactors, chimneys, feed gas preheater, galvanizing tank, etc. like products are manufacturing company located at New Mumbai. The major problem faced by this firm is inventory control, scrap management, store management, poor utilization of space, poor material handling. There is high flow intensity between the departments which have high interrelationship. This leads to high travelling time which increases the travelling cost which in turn decreases the overall productivity of the company. An alternative layout is proposed by using the steps in Systematic Plant Layout, which is the systematic way of generating layout alternatives. The proposed layout involves optimizing the departments which have high interrelationship and close to each other. The proposed alternative layout is further evaluated by using Pugh matrix. The layout is chosen based on the performance measures which have the most significant improvements in the facility. Later after implementing the modified layout 5S is also implemented simultaneously based on the steps as discussed in this thesis to manage the facility. Keywords: Systematic plant layout, algorithms, material flow, CRAFT, CORELAP, from-to chart, activity relationship chart, fabrication, Pugh matrix, 5S, lean manufacturing, quality, waste.