Abstract:
For continuous improvement in an organization, Japanese philosophy Kaizen is very popular.
flawless. Concepts of kaizen methodology and proper implementation of tools can lead to a
successful kaizen program in a company. Various other companies also adapt to various
disciplines and methods as per need and ease of application. Few are JIT ( Just In Time),
Manufacturing organizations typically have raw materials, components, sub-assemblies, tools
and equipment’s; semi-finished goods etc., the inventory of an item should not be neither too
high nor too less. It should be optimal. The recent development in inventory management is JIT
(Just-in-Time). JIT implies handling of inventory in a much disciplined way. It requires changes
in culture. It also encompasses the Japanese managerial characteristics i.e., Lifetime
employment, implicit control.The design of assembly lines is an important issue in
manufacturing engineering management and control. The idle time is the most interesting
performance index for assembly line design. The classical simple line-balancing problem
(SALBP) consists of assigning tasks, necessary for processing a product, to workstations such
that the idle time (number of stations, cycle time, cost) is minimized while precedence
constraints between tasks are satisfied. From the worst-case analysis point of view, the SALBP
problems are NP-hard in strong sense. In this company initial the concept of Line Balancing
was tried to implemented but due to unnecessary hardships of shifting of stations a new concept
was learnt and applied in the company. New concept which was implemented was 'The Concept
of 5S’. 5S is a basic foundation of Lean Manufacturing systems. It is a tool for cleaning, sorting,
organizing and providing the necessary groundwork for workpiece improvement. This paper
dealt with the implementation of 5S methodology in the small scale industry. By following the
5S methodology, it shows significant improvements to safety, productivity, efficiency and
housekeeping. The improvements before and after 5S implementation is shown by pictures in
the paper. It also intends to build a stronger work ethic within the management and workers
who would be expected to continue the good practices.
