5S Activity Roadmap 28 June_2011

7/31/2019 5S Activity Roadmap 28 June_2011

1/24

Sh

ee

t

Me

tal_Ben

ding

Inco

ming

Inspec

tion

Mach

ining

Ma

ine

nance

Bo

ttom

Ro

ller

Sec

tion

-Ass

ly

Mec

h.

/Elec

t.Ass

ly

July

Aug.

Sr. No. Activity

5.1 Restructuring of 5S Orgn. Structure.

5.1.1

Restructuring of Steering committee

and nomination of 5S Champion &

Facilitators.

5.1.2 Zone formation / Zone restructuring

5.1.3 Provision of 5S Visual ImplementationDisplay Boards.

5.2.1Development of system for 1S

implementation.

5.3.1 1S Training of all members.

5.4.1 1S implementation at all teams

5.5.1Progress review of 1S implementation

level.

5.6.1 1S audit by Kaushal Associates.


implementation

5.3.2 2S Training of all members



level



implementation.

5.3.3 3S Training of all memebers



level

5.6.3 3S audit by Kaushal Associates

5.7 Sustenance of 1S / 2S / 3S system

5.84S - Standardisation of good practices

followed

July. 1st

Week

AD

AD

AD

July. 1

st

Week


2/24

Heads

toc

k/

Foo

tsto

ckAss

ly

Laser

Cu

tting

Welding

Stores

Raw

Mate

ria

lStores

Finish

Goo

ds

Stores

Pac

king

ShotB

las

ting


3/24

Sh

ee

t

Me

tal_Ben

ding

Inco

ming

Inspec

tion

Packing

Area

Ca

libration

La

b.

Managem

en

tOffice

IMS&SQEOffice

Mac

hining

Ma

intenance

Nov. Dec.

Sr. No. Activity


5.1.1

Restructuring of Steering committee

and nomination of 5S Champion &

Facilitators.


5.1.3 Provision of 5S Visual ImplementationDisplay Boards.


implementation.




level.


5.2.2 Development of system for 2Simplementation




level



implementation.




level5.6.3 3S audit by Kaushal Associates


5.84S - Standardization of good practices

followed

3

4

1

1

2

2

Sept. Oct. Nov.


4/24

Bo

ttom

Ro

ller

Sec

tion

-Ass

ly

Pac

king

Mec

h.

/E

lec

t.Ass

ly

Heads

toc

k/

Foo

tsto

ckAss

ly

Pow

der

Coa

ting

Laser

Cu

tting

Welding

ShotB

las

ting

Stores

Raw

Mate

ria

lStores

Finish

Goo

ds

Stores

Pla

ting

Jan. Mar. May Jul

4

Aug.

1

2

2

3

3

4 3

4

1

2

3

1

2

Jun

1

1

2

3

2

3

4

Apr.Feb.

1

1

2

4

3

4

1

3

1

1

2

2

1

1

2

1

4

2

3

3

4

2

2

3

3

4

4

4

1

1

2

2

1

2

2

1

1

4

1

2

3

3

2


5/24

Departmen

t

Shee

t

Me

tal_Ben

ding

Incom

ing

Inspec

tion

Mac

hining

Ma

inenance

Bo

ttom

Ro

ller

Sec

tion-

Ass

ly

Pac

king

Mec

h.

/Elec

t.Ass

ly

Hea

ds

toc

k/

Foo

tstoc

kAss

ly

Pow

der

Coa

ting

Laser

Cu

tting

We

lding

Sho

tBlas

ting

Stores

Raw

Ma

teria

lStores

Sr. No. Activity


5.1.1 Restructuring of Steering committeeand nomination of 5S Champion &

Facilitators.


5.1.3Provision of 5S Visual Implementation

Display Boards.


implementation.




level.



implementation5.3.2 2S Training of all members



level



implementation.




level




followed

April

Oct.

Aug.

July Sept.

Sept. Nov.

Dec.

Jan.

Nov.

March

Roadmap for 5S implementation

Jan.

Feb.

March May

J


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Plating


7/24

Location / Teams / Areas Resp.

S.N.

1Top Management Office

(2nd Floor)5S

2 Sheet Metal_Bending Mr. Arali Pravin 5S

3 Incoming Inspection Mr. Shelar Anand 5S

4 Packing Area Mr. Ajay Kamble 5S

5 IMS & SQA Office Mr. Sachin Pawar 5S

6 Calibration Laboratory Mr. V. Shelke 5S

Machining / Turning Mr. Rao / Mr. Deshpande

Maintenance Mr. Bhandare

Bottom Roller Mr. Pisal

Section - Assly Mr. Arvind Shetty

Mech. / Elect. Assly Mrs. Jyoti Kulkarni

Headstock / Footstock Assly Mr. Sutar

Packing Mr. Ajay Kamble

Powder Coating Mr. Gole Vilas

Laser Cutting Mr. Arali Pravin

Welding Mr. Kondhekar Sagar

Shot Blasting Mr. Arali Pravin

Stores Mr. Shaha

Raw Material Stores Mr. Gavali

Finish Goods Stores

Plating Mr. Jagdale

1S 2S 3S 4S

4S

1S 2S 3S

1S

1S 2S 3S

4S

4S

1S 2S 3S 4S

Roadmap For 5S implementation

Pilot Areas:

Month Aug Sep Oct

Other Additional areas / teams:

Mar Apr

1S 2S

Nov Dec Jan Feb

2S 3S

3S

4S


8/24


9/24

Aug Sep Oct


10/24

Sr.

No.Process Area Sub-Process Area

Bending ShopLaser Shop

Welding

Powder Coating

Shot Blasting

HMC

VMC

Tool Room

CNC

Cutting Area

Line

Plating

Section Assly.

Mech. Assly.

Elect. Assly

Head Stock / Foot Stock Assly

Blow Room

6 IED Tool Crib

Workshop & Office

Maint. Stores

Utilities

Incoming Inspection

Product Quality

Calibration & CMM

Meta. Lab.

Sheet metal Quality

B/O stores

R. M. Stores

F.G. Stores

Packing

Canteen

Outside / Peripheral areas

Shop_floor areas

Quality8

Process Wastage

1 Sheet Metal

2 Machining Centre

3 Turning Centre

Bottom Roller

Assembly5

7 Maintenance

Stores & Logistics9

4


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Security & Parking

House-keeping

Garden & internal Road

Scrap Yard

ETPGuest House

Rej. Area - Mech.

Supplier Rej. Area - Sheet metal

13 Assembly Assly. Office

14 Quality Quality office

15 IED Production+ 301 Room + Battiwala office

HR office & ReceiptionMedical & Library Room

House-keeping, Toilets

17 IT IT office & IT Stores

18 Supply Management Office & Stationary Room

19 IMS & VQA Fro. Cabin & IMS office

Office of T. Haegi

Ofice of A. Gharat

Office of T. Gulati

Finance office & company secretary

Record Room

22 R & D R & D Office

23 Project & Facility Project & Facility

Total 23 Areas Total - 55 Sub_Areas

21 Finance

HR & Shop Floor office areas

16 HR

First Floor office areas

Second Floor office areas

20 Top Management

12 Quality

10 HR

11 Facility


12/24

Sr. No. Sub-Process Area July Aug. Sept. Oct. Nov.

1 Bending Shop

2 Incoming Inspection

3 Packing

4 Fro. Cabin & IMS office

5 Office of T. Haegi

6 Maint. Stores

7 R. M. Stores

8 Laser Shop

9 Welding

10 Powder Coating

11 Shot Blasting

12 HMC

13 VMC

14 Tool Room

15 CNC

16 Cutting Area

17 Line

18 Plating

19 Section Assly.20 Mech. Assly.

21 Elect. Assly

22 Head Stock / Foot Stock Assly

23 Blow Room

24 Tool Crib

25 Workshop & Office

26 Utilities

27 Product Quality28 Calibration & CMM

29 Meta. Lab.

30 Sheet metal Quality

31 B/O stores

32 F.G. Stores

Project Name :

Process Wastage Month


13/24

33 Canteen

34 Security & Parking

35 House-keeping

36 Garden & internal Road

37 Scrap Yard38 ETP

39 Guest House

40 Rej. Area - Mech.

41 Supplier Rej. Area - Sheet metal

42 Assly. Office

43 Quality office

44ro uct on+ 301 oom + att waa

45 HR office & Receiption46 Medical & Library Room

47 House-keeping, Toilets

48 IT office & IT Stores

49 Office & Stationary Room

50 Ofice of A. Gharat

51 Office of T . Gulati

52nance o ce company

53 Record Room

54 R & D Office

55 Project & Facility


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Dec.


15/24

DepartmentResponsib

ility

Sheet

Metal

Bending

Incoming

InspectionPacking

Mr.

Haegi's

Office

Calibrat-

ion lab.

IMS

Office

Sr. No. Activity


5.1.1Restructuring of Steering committee and

nomination of 5S Champion & Facilitators.


5.1.3Provision of 5S Visual Implementation

Display Boards.


implementation.



5.5.1 Progress review of 1S implementation level.



implementation



5.5.2 Progress review of 2S implementation level



implementation.



5.5.3 Progress review of 3S implementation level




followedNov.

Roadmap for 5S implementation

Aug.

Sept.

Oct.

July


16/24

Remarks


17/24

Project Name

Month July Aug. Sep. Oct. Nov. Dec. Remarks

Activity Respons.

Formation of Steering committee and

nomination of 5S Champion

Team formation for Pilot Areas

Provision of 5S Visual Implementation

Display Boards.

Development of system for 1S

implementation.

5S Training of all members.

1S implementation at all teams

Progress review of 1S implementation level.

1S audit by Kaushal Associates.


implementation


Progress review of 2S implementation level

2S audit by Kaushal Associates.


implementation.


Progress review of 3S implementation level

3S audit by Kaushal Associates

Sustenance of 1S / 2S / 3S system by Pilot

Areas

4S - Standardisation of good practices

followed

Identification of other additional areas /

teams in Shop-floor / Office

: 5'S Implementation.

Pilot Areas

1) Sheet Metal Bending, 2) Incoming Inspection,

3) Packing Area, 4) Top Management Office (2nd floor),

5)IMS & SQA office 6) Calibration Lab.


18/24

Location / Teams / Areas Resp.

S.N.

1Top Management Office

(2nd Floor)5S

2 Sheet Metal_Bending Mr. Arali Pravin 5S

3 Incoming Inspection Mr. Shelar Anand 5S

4 Packing Area Mr. Ajay Kamble 5S

5 IMS & SQA Office Mr. Sachin Pawar 5S

6 Calibration Laboratory Mr. V. Shelke 5S

Other Shop-floor areas

Other Office Areas

Other peripheral / outside areas 2S1S

1S 2S 3S

1S 2S 3S

AprNov Dec Jan FebSep Oct

2S 3S

Other Additional areas / teams:

Mar

3S

4S

Roadmap For 5S implementation

Pilot Areas:

Month Aug

4S

1S 2S 3S 4S

1S 2S 3S

1S 2S

4S

1S 2S 3S 4S

4S

1S 2S 3S

1S


19/24


20/24

5S

5S4S

Aug Sep Oct


21/24

From To 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

1 6 3 5 7 `

2 1 8 8

1 1 9 9

12 6 10 15

2 1 16 16

2 1 17 17

5 3 18 20

12 6 21 26

11 5 27 31

13 7 32 38

3 1 39 39

7 4 40 43

15 7 44 5051 52

1 4

Straightening

April

Other Dec.

Shot-Blasting

Work Centre Approach

Bending

WeekSr.

No.Work Centre Qty.

Total Week

Required

Cutting

Grinding

Laser Cutting

Punching

Welding

Other

VMC

HMC

CNC

End of 2012

2013

Remarks

Feb.

April

Aug

Aug

Mar-12 Apr-12 May-12 JFeb-12

S

h

e

e

t

M

e

t

a

l

M

a

c

h

C

u

b

6

M

a

c

h

R

n

d

Assly 13


22/24

6 7 8

eb-13


23/24

From To 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

6 2 5 6

2 1 7 7

1 1 7 7

12 4 8 11

2 1 12 12

2 1 13 13

5 2 14 15

12 4 16 19

11 4 20 23

13 4 24 27

3 1 28 28

7 2 29 30

15 5 31 35

4 1 36 36

4 1 37 37

5 2 38 39

Feb-12

M

a

c

h

R

n

d

A

s

s

e

m

b

l

y

Mar-12 Apr-12 May-12

Apr-12

Jun-12

Jun-12

M

a

c

h

C

u

b

Laser Cutting

Punching

Remarks

Feb-12

Sep-12

Sep-12Section assly &

packaging

Top Arm Assly.

Other

Other

VMC

HMC

CNC

Cutting

Grinding

Welding

Shot-Blasting

Work Centre Approach

Bending

WeekSr.

No.Work Centre Qty.

Total Week

Required

S

h

e

e

t

M

e

t

a

l Straightening

Dep.

1

2

3

4

Mar-12

Other Aug-12


24/24

40 41 42 43 44 45 46 47 48 49 50 51 52

Nov-12Oct-12 Dec-12

Documents

5S Activity Roadmap 28 June_2011