Abstract
The main purpose of this studies is to utilise the development of the 5S concept in workshop to lift the organization management. This study also will explain the technique of lean concept which uses to increase the efficiency of tools management. They all need to understand all the benefits that everyone will derive from a better workplace.
Furthermore, it is also helped students to recognize about the 5S culture in workshop to keep the surrounding in order and have a minimum standard to achieve. This standard could improve the workshop safety and reduce fault while doing a task.
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CHAPTER 1: INTRODUCTION
1.1 Introduction
“Seiketsu” or standardized is fourth step of the 5S concept. It characterized as build up a work structure that will bolster the new practices and influence it as a part of the daily routine. This step is the most ideal approaches to practice sort, set in order and cleaning idea. It supports another 3S in the methodology which are the sort, set in order, and shine concept for guarantee that consistent cleaning on working environment are done, useful objects are kept, and tools are stored in their legitimate place.
1.2 Problem Statement
The arrangement of the tools and equipment in the workshop are not properly order and adjusted in light of standard. It could be one of reason that can influence work execution. The reason to implement 5S culture are to improve the performance and organize the entire system to achieve a standard.
In Aviation industry, little entanglements and mistakes will lead to accident that can cause fatal injury. It is important to avoid any mistakes while doing task on aircraft. The 5S is the strategy of creating and sustaining well organized, effective and quality workplace. It results as improvement of quality and safety of work, likewise go about as stepping stones to create a strong housekeeping culture in the organization.
1.3 Objectives
To overcome the problem statement, several objectives has been listed out:
• To ensure that the tools and equipment are in order based on a standard.
• To apply and maintain regular basis before and after doing a task.
• To enhance the safety workplace and the quality of the task.
1.4 Scope
The scope of this venture is to have a standard system and practices at University Kuala Lumpur Malaysian Institute of Aviation Technology B-1-07 & B-1-08 workshop that utilization for safety wire locking and corrosion treatment practices. By having the “Seiketsu” methodology it will be simpler to carry out practical as it has technique to store tools and equipment, cleaning and easy to maintain by using naming and numbering to keep the equipment in organized way.
CHAPTER 2: LITERATURE REVIEW
2.1 Overview
The purpose of this literature review is to provide background data on the issues to be considered in this thesis and to emphasize the relevance of the present research. This section clarifies briefly about the 5S methodology and the benefits of this framework. This part also explains in detail about the equipment and methods that has been used to complete this final year project.
2.2 History of 5S
Developed by Hiroyuki Hirano in Japan, it was known as one of the techniques that empowered what was then termed “Just in Time Manufacturing”. Numerous Western companies coming across the approach for the first time found the experience one of enlightenment. They had constantly known the role of housekeeping within optimised manufacturing performance and had always known the elements of best practice. However, Hirano provided a structure for improvement programs. He pointed out a series of identifiable steps, each building on its predecessor.
Phase of 5S represent five steps in the system, starting with the letter S; “Seiri”, “Seiton”, “Seiso”, “Seiketsu”, and “Shitsuke” as in Figure 2.1. Each phase defines different methods that need to be done to achieve a systematic framework for organization.
Figure 2.1: 5S phases
2.2.1 Seiri
The first phase of 5S is Seiri (sort). In this process the main idea is to sort all the unnecessary items that are not required in the region, mark all the items and then dispose these items or re-put them into another work station as in Figure 2.2 and Figure 2.3. Just what is required at a given station ought to be kept in this way it could authorizes space for doing task. A proper name and one-location storage should be assigned to each item for reducing confusion, resulting in maximum efficiency.
Figure 2.2: Before sorting
Figure 2.3: After sorting
2.2.2 Seiton
The second phase of 5S is Seiton (set in order). After all the unnecessary items are arranged, it is time to start organizing the area to expand the work ergonomics and overall safety in the work area. It is study of how efficiency to get things and put it away after used as in Figure 2.4. Organized work spaces are important to get easy access and limit body movement during perform a work.
Figure 2.4: Example of set in order
2.2.3 Seiso
Seiso (shine) as third phase of 5S, represents routine cleaning of the work area, tools, and equipment after utilized. A clean work area prevents clutter or dirt from concealing potential problems and enhance the working life of equipment as in Figure 2.5. Tidiness is also useful to notice damage on equipment as in Figure 2.6. In aviation industry, foreign object damage (FOD) are prohibited claiming could prompt aircraft mishaps.
Figure 2.5: Example of seiso
Figure 2.6: Cleaning workplace after task
2.2.4 Seiketsu
The fourth phase is Seiketsu (standardize), implies making all the initial 3S a routine practice by prepared the standard operating procedures (SOP). This phase is there to set basic, visible guidance, how the area ought to be kept on daily schedule. One most popular way to keep up the standard by 5S audit in different time periods. The results from the audit could determine any issues and actions to overcome it.
Figure 2.7: A standardized practices
Figure 2.8: An organised work space
2.2.5 Shitsuke
The last phase is Shitsuke (sustain) that requires ongoing effort or discipline to strictly follow the procedure in conjunction to maintain 5S concept in organizations. The progress of 5S must be kept track for assessments and improve the principles by having 5S corner as in Figure 2.9. Everyone in organization are required for practice the idea based on the schedule as in Figure 2.10 until wind up the culture.
Figure 2.9: Example of 5S corner
Figure 2.10: Example of 5S schedule board
2.3 Advantages
5S is a structured approach to deal with getting a working environment cleaned up, sorted out, standardized, creating efficiency instead than waste, and sustaining improvements made.
These are few benefits from 5S concept:
i. Increase effectiveness and productivity of work
ii. Reduce error and increase workplace safety
iii. Boost worker moral to spur them for better work result
iv. As an image of excellent organization
CHAPTER 3: METHODOLOGY
3.1 Introduction
This methodology section provides the fundamental data of the procedures by which the project has been finished. To turn out with great result for this project, every progression has been taken and documented in this chapter. This venture has been managed accordingly to what has been planned and in perfect order. Therefore, the detailed description of the procedures and the rational of why and how it has been done are explained.
3.2 Methodology Diagram
The system was designed in the following stages to meet the requirement of Final Year Project which divided into 5 stages:
Table 3.1: Methodology diagram
3.3 Phase 1 – Idea development
This project is tied in with implementing a standard concept in a workshop. This concept needed to put on for making the workshop cleans and organized. The plans to spread this concept are sort the equipment based on its function, painting, labelling and drawing layout diagram.
3.4 Phase 2 – Understanding
The research has been made to discover proper method and identify how the 5S perform for completing this final year project that are guided by supervisor, technicians and coordinator. The materials chosen are essential equipment to ensure that the project can be finish as planned. A research is done to determine the type of colour coded that be used for this project. Different colour brings different meaning in 5S principles.
3.5 Phase 3 – Analysis
After doing some research, the next step that should be taken is to analyse on how to generate the outcome from the idea appropriately. The procedures are done appropriately according to the plan to avoid from doing any mistakes during this project. The right determination of materials is resolved.
3.6 Phase 4 – Sourcing
After the project has been analyse, all the equipment need to buy for completing the project has been listed out. The equipment needed to complete the project are:
Equipment Quantity
Masking tape 6
Captain Gloss paint (yellow) 1L x 1
Captain Gloss paint (green) 1L x 2
Paint brush 2
Paint Roller 2
Paint thinner 1
A4 paper 20 pieces
Paint marker (white) 2
Table 3.2: Equipment needed for this project
The uses of the yellow and green paint are to paint the tools board, and the base of the safety wire locking and corrosion treatment racks. The colour chosen to make a contrast and visible for equipment arrangement.
Figure 3.1: Masking tape
Figure 3.2: Captain Gloss paint
Figure 3.3: Paint brush
Figure 3.4: Paint Roller
Figure 3.5: Paint Thinner
Figure 3.6: A4 papers
Figure 3.7: Paint marker
3.7 Phase 5 – Finishing
The final step of the methodology is finishing. Finishing is the process where equipment racks and tools board being painted, marked and labelled using proper procedure that has been guided by the technicians.
3.7.1 Painting
Procedure:
1. Wear personnel protective equipment such as mask and goggles.
Figure 3.8: Safety goggles
Figure 3.9: Safety mask
2. Do the measurement 1.5 inches for the border.
3. Mask with masking tape to avoid paint overlap. Then apply the yellow paint for first coat.
4. Let the paint within 30 – 45 minutes
5. Apply second coating to spread the paint evenly.
6. Let the paint fully dry.
After the yellow paint fully dry, paint the centre area with green colour. Same procedures are applied for the green paint.
Figure 3.10: First coat of yellow paint
Figure 3.11: Second coat of yellow paint
Figure 3.12: First coat of green paint
Figure 3.13: Second coat of green paint
3.7.2 Drawing Layout Diagram
White paint marker is being used to marking the layout of the equipment after the racks has been painted as in Figure 3.7 and Figure 3.8. The layout diagram acts as a guideline to arrange the equipment aligned to each other. The tools are place according to the guideline to keep them straight and organized.
Figure 3.14: Drawing a layout
Figure 3.15: A complete layout diagram
3.7.3 Labelling
The final finishing is naming and numbering on each tools and equipment section. The label has been printed out and laminated to ensure it not easy to tear out. The numbering will be used to audit the equipment quantity as in Figure 3.9 and Figure 3.10.
Figure 3.16: Tools labelling
Figure 3.17: Equipment numbering
3.8 The flow of the chart
Table 3.3: The flow of the methodology
CHAPTER 4: RESULT AND DISCUSSION
4.1 Introduction
This chapter is all about the result for this final year project. The main objective for this project are to the workshop environment more organized and safe. All the figures show the difference between before and after seiketsu concept are applied.
4.2 Result
Finally, the project has been completed successfully. Some difficulties and challenges were encountered throughout completing the project such as finding the right tools and equipment, finding suitable type of paint, and pack class schedule. Despite all of that, the problems have been managed by guidance from supervisor and the studies that has been carried out.
4.2.1. Before implementation of seiketsu
Figure 4.1: Before implement of seiketsu
Figure 4.2: Before implement of seiketsu
4.2.2 After implementation of seiketsu
Figure 4.3: After implementation of seiketsu
Figure 4.4: After implementation of seiketsu
Figure 4.5: After implementation of seiketsu
4.3 Discussion
In view of the result, all the figures obviously show the difference when the 5S idea be drilled. All the tools and equipment are more organized than previously. Besides, all the project objectives have been accomplished successfully. This undertaking could roll out a great deal of improvements to the students for their learning material and practices purpose in University Kuala Lumpur Malaysian Institute of Aviation Technology.
CHAPTER 5: CONCLUSION
5.1 Summary
From the beginning of this project, the first objectives that need to be achieved is to ensure that the tools and equipment are in order based on a standard. Based on the result, this objective has been achieved after the 5S concept is applied.
In addition, the second objective of this project is to apply a regular cleaning routine after doing a task. By having out a layout diagram, it will be easier to organize the tools in it legitimate place. After gathering all the information regarding this project, the implementation of this standardized concept has been started.
The third objective of this project is to improve safety of the workplace and the quality of a task. This will avoid error and minimize the body movement to complete a practice. Furthermore, equipment also easier to audit when they be labelled. Old arrangements are hard to detect problem because they are less systematic. So that, the probability that can lead to mistakes are high. This problem has been solved by labelling all the tools and equipment in the workshops.
Besides, this project also can help the students to gain knowledge about the benefits of 5S concept and can applied it in when working in the industry.
5.2 Future recommendation
This project has the limitation that can delayed its project. For future recommendation, the workshops need go through 5S audit to sustaining the routine and improve its effectiveness.
Furthermore, creating a cleaning schedule also a good step for ensure the workshop always in good condition. This could lead to a conducive environment and enhance the quality of product produced.