Productivity enhancement using systematic layout planning and monitoring 5S strategis

Abstract

Small scale industries play an important role in the Indian economy. After agriculture, it has emerged as a powerful tool in providing relatively large employment. The objective of this thesis is to improve the productivity of a company using systematic layout planning and to increase organizational performance by monitoring 5S strategies in a forging company named as Magmachino forge Pvt. Ltd. located in Thane-Maharashtra, which is popular in manufacturing and exporting precision machined components. The major problems faced by the company is a poor utilization of space, poor material handling, and poor time management, due to lack of following the principles of 5S and effective plant layout. There is a real need for empirical studies in the field of the new management system and their impact on a company. In this report, we provide a detail definition of 5S and plant layout; and listed efficient utilization of resources, manufacturing and maintenance ease, enhanced productivity, effective utilization of space, material and time, as well as the increase in efficiency and overall cost. In this report an alternate layout is proposed using activity relationship chart which involves transferring the departments which have high interrelationship close to each other and flow of material, But this does not help in tackling the problems faced by the company due to which we have monitored and implemented 5S technique as it plays an important role in continuous improvement in today’s organization. Surveying method is used for data collection which is done by distributing a questionnaire among the workers and owner. The result shows after implementation of 5S it improves organizational performance in day to day working environment and proposing layout results in smooth material flow, efficient utilization of floor area and increase in the area which can be used for more products simultaneously. The final evaluation results show after applying 5S and plant layout strategies, it improves the overall efficiency of the company and cost per manufacturing of a product piece. Keywords: Organizational performance, Utilization, surveying.