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Global Manager Group had successfully completed 5S implementation project in Roto Moulding Department of Sintex Industries. During this 3 Months consultancy, GMG has implemented 5S Japanese techniques for lean manufacturing, arranged training sessions for more than 600 employees of the company that guided them to understand each S requirements in brief, which resulted in successfully completion of 5S Lean management system within given time limits. The 5S training sessions are arranged by Sintex Industries to create vibrant culture in the roto moulding department of the organization with the help of 5S Lean training by Global Manager Group.

5S training with Implementation in India

Successfully delivered 5S training to Employees of Sintex Industries

GMG has helped and divided total area of roto moulding in to 12 zones and each zone are divided with zone wise teams and implemented 5S Japanese techniques for lean manufacturing. Total more than 600 employees are trained, work instructions and audit checklists as well as cleaning forms and SOP are prepared and 3 months consultancy is provided by GMG.

The key implementation covered during the 5s project in Roto Moulding Dept of Sintex industries are:

  • Electric diagram, gas diagram as well as water diagram is prepared and proper wiring completed and diagrams displayed. Unused pipeline approx 400 meter pipes are removed.
  • All moulds, jigs, fixtures list is prepared and unnecessary items are removed. Now moulds are available with location list. This will provide lot of space available for other activities
  • All machines complete preventive maintenance schedules are prepared and started.
  • All processes and cleaning work instructions are prepared and, displayed
  • Process parameters for all the items are defined and processes are standardized
  • All display boards, work instructions and visual aids with photographs for do’s and do not created quality culture to sustain this results
  • Leakage of powders from many places are taken in control, Trial successful for major leakage from housing on machine no. 9 and same will be done for all other machines
  • In all the areas Objectives/Key result areas are made, displayed graphically on monthly basis and started monitoring
  • Proper cleaning culture created which may take care for final product finish and quality issues to reduce defects. Also Cleaning checklist records are started.
  • Underground cable trenches cleaned and approx 500 meter of unnecessary cables are removed
  • Many places white sheets are put and this makes proper lighting in day time. This will save lot of energy

The key focus of the 5S training is to develop and learn Lean 5 S and 5 weeks was declared for each S of Japanese techniques and then auditing is done by team of auditors in different shifts. The participants had satisfied with the knowledge shared by Mr. Devang Jhaveri about 5S Lean work culture as well as real time examples and case studies provided for continuous learning system implementation. Throughout the 5S Lean sessions all the management, technical and associated staffs learns to implement lean management system in daily routine work at organization. Also at the end of the training session workshops and exam is taken to evaluate the participants’ performance. Also prizes are declared to the best performing personnel and good suggestions given by workers by owner of Global Manager Group.

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