Some Important Tools in Industrial Engineering at Garments Industry & Simplify & Clarify These Tools with Short Definition. Part- ii

MethodStudy: Method Study is a systematical recording and critical examination of ways of doing things in order to make improvement.

Method Study is the Process of subjecting work to systematic, critical scrutiny to make it more effective and/or more efficient. It is one of the keys to achieving productivity improvement.

That is

It is a systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs.

Motion Study: Motion Study involves the analysis of the basic hand, arm and body movements of workers as they perform work.

Motion Study is designed to determine to best way to complete a repetitive job.

That is

Motion Study Measures distance or how much you move to do a job and how much you get done in a period of time.

Work Measurement: Work Measurement is concerned with investigating, reducing and eliminating ineffective time, whatever may be the cause.

Determine the time necessary to perform a job and its elements.

The application of technique designed to establish the time for a qualified worker to carry out a specified task when working in a defined condition.

 Md. Farid Ahmed
IE Officer
Fakir Apparels Ltd.
BSCIC Industrial Area, Enayet Nagar,
Fatulla, Narayangonj, Bangladesh.
Contact : +8801814220987
Email: farid.ieconcern@gmail.com

Lean Tools | 5S | 3rd S Seiso or Shine | Definition and Technique For Implementation.

After completion Seiri and Seiton (that are the 1^st two steps of Lean tools 5S), Now the next step is to implement the third Seiso or Shine.

Seiso is the third stage of 5S (Lean’s Most effective tools) method. Seiso (to make everything shiny clean) is a term that suggests you a highly productive work environment should be clean. Seiso is a Japanese word which means shiny, sweeping or cleaning or systematic cleaning, when using 5S refers relates to cleaning workplace and all equipment and keeps it clean, neat and systematized.  Seiso means remove dust and dirt from a workplace. This 5S (Seiso) is being an operative Lean Manufacturing apparatus which helps with not just your housekeeping, but with enhancing your efficiencies, improving  safety, and ensuring standardized ways of working. 5s benefits are based around the fact that it will help to remove the S7even wastes of Lean engineering from the manners. It has also an advantage to inspecting the apparatuses during the cleaning period, whereby leakage problems, breakdowns, failures, or any type of leakage are identified.

Seiso has 2 most important goals. Those are:

1. To set the new Level for cleanliness.

2. To learn how to keep up that level of cleanliness.

Cleaning is thoroughly related to the proper functioning of the apparatus and the ability to produce quality goods.

Implementation:

For Implementing Seiso, it requires,

1. At 1^st we need to identify the source of dirt and contagion to take root shares for throwing away. Otherwise it would be impossible to keep clean and in good working area.

2. Add cleaning as a part of daily work. A regular cleaning process can be used as a visual inspection of apparatus or the workshop capability. Just as you might notice corrosion or a scrape when washing your car – and not notice it if you just get in and drive – so the workers will have opportunities to catch problems in their early stages. As an example: we had to clean a small puddle of hydraulic fluid – what does this mean about the state of the apparatus?

Even this one-time activity links in with the previous steps of Seiri and Seiton. While acting the one-time "shiny clean" activity, the work teams should ask themselves questions and note the answers:

1.      Does dirt cause problems in operating the apparatus?

2.      Is gravel causing the machinery to wear rashly?

3.      Is the work station clean enough for safety and comfort?

4.      What does the "grime" tell us about the apparatus (like the leaking hydraulic fluid example)?

5.      Is the "mud" – especially powder, gas or liquid – harmful or toxic?

6.      What apparatuses, chemicals or procedures are appropriate?

7.      Could uncaring scrubbing actually damage the apparatus?

8.      Could we implement routine maintenance – like checking the engine oil when washing your car – be executed while cleaning?

9.      Was "clay" hiding any problems, such as decomposing apparatus or uneven floors?

This Seiso steps should be functional before a factory setting and before physical cleanliness. For example guess an office partition. Is dirt adding on a picket of papers? Why are the papers sitting there, relatively than being filed appropriately? Are the computer’s air outlets congested? Are outmoded booklets stored on the computer relatively than on a network backup?

We know that the Seiso step is one time assignment. So it must be documented.

The benefits from The Third 5s-Seiso:

1.      Setting the standard for future cleanliness.

2.      Less lost time for maintenances, since apparatus will be inspected concisely but frequently, and because there will be less grime clogging the apparatus.

3.      Reduce potential risk of accidents.

4.      Improving the physical and mental welfare worker.

5.      The useful life of the apparatus is increased to inhibit any decline from pollution and dirt.

6.      The cleaning leads to a significant increase, in overall apparatus are in top form cleaning.

7.      Wastage of materials and energy due to the abolition of leaks and leaks are reduced.

8.      The quality of Productions is upgraded and losses are avoided by dirt and contagion of the product and packaging.

Main benefits of a Seiso stage come with what is learned:

1.      Actually acting the work validates what was planned – or extends the planning with reality.

2.      Lists of.

3.      Tasks.

4.      Tools, apparatus, detergents or cleansers required for each task;

5.      Series of tasks – wash the machinery before swabbing the floor.

6.      Actual times required by the various chores.

7.      Maintenances required, as noted during the inspections.

8.      Ideas for development – when you do the cleaning yourself you will acquire ideas on how to make the work easier in the future

9.      Employee buy-in: they did the work and therefore they know it can be done and how long it took to do it the first time.

    Written By:
Md. Farid Ahmed
IE Officer
Fakir Apparels Ltd.
BSCIC Industrial Area, Enayet Nagar,
Fatulla,Narayangonj, Bangladesh.
Mobile: 8801814220987
E-mail: farid.ieconcern@gmail.com

Lean Tools | 5S | 2nd S Seiton or Set In Order | Definition and Technique For Implementation.

In My Previous page I was trying to discuss about 1^st S (Seri or Sort) from the Japanese 5S System, which is the Lean System’s 1^st Fundamental Principle. In this I want to discuss about the 2^nd S, Seiton or Set In Order. It is also called Straightening or Organizing or Orderliness. That is, setting everything in proper order for easy reclamation.

It involves setting in order what is sorted in Seiri, straighten and standardization of it. Where Seiri subsumed getting rid of the things that you do not need or necessarily, Seiton ensues closely on by assuring what you remove is orderly and available where and when you need it. 

Seiton means orderly placing the objects away after you have used them. Placing objects away requires following 3 rules:

1.       Fix where objects belong,

2.       Decide how objects should be put away,

3.       Follow the put-away rules to leave objects where they can be quickly and properly found next time they are needed.

To fix the put-away rules, do an analysis of how the objects are used. Pay particular attention to when and how they are picked up and used. This is the initial conductor of how and where they are put away. If something used 50 times a day, then this multiplies the time wasted in finding, the finding the item and taking it to where it is to be used. Seiton’s determining where and when objects are needed, placing them in a way that promotes efficient work flow. A worker should not have to hunt for necessary tools, or walk to another area to access often-used items.  

Now let’s find out how it is working?

The object of Seiton is that everything should be stored competently. Practically, this means, store the objects where they will be used. The more frequently it is used , the closer It should be kept. And reduce clutter by storing rarely used items further away. 

Visual Communication of Seiton:

Where confusion exists about the objects, then it should be identified in some way. For example, when selecting something is uniquely marked, for example, with standardized numbers or colors, then error and following wastes can be eliminated. The visual identification and communication are also critical to Seiton implementation. Objects that are used frequently, must be  labeled to document dates of use to determine priority of location. Items are labeled so that there no mistakes will happen. Labelling and naming should be similarly standardized. Each and every label must be located where this object  belongs to.  Seiton should be clearly communicated to the correct location.

Seiton Keep the most frequently-used objects right in the sequences:

1. Handy

2. Visible

3. Easy to reach

4. Easy to put back when not needed.

Daily or Monthly objects might be kept somewhere in the belonging marking area. You may use store room, but this storage area should still be visible from the area of the work station. Rarely-used objects or spare parts could be stored away from the work station.

Now we need to build a culture. It is one thing to set up storage areas. It is another to have people use them properly. Management must begin implementing a culture where workers, as a matter of course and a matter of pride:

1. Store Objects where they belong.

2. Keep the work area tidy.

A misplaced object will be visible at a glance in a well run factory.

When we are Doing the job Seiton or Set in Order, there should be needed to raise some questions.

1.    How often is it used?

2.    Is it easy to reach the items?

3.    How to Store it? And

4.    How to maintain it every day properly?

Usefulness to use Seiton:

1.   Increase productivity by decreasing the time spent retrieving an object.

2.  Cost savings because lost objects do not need to be re-ordered.

3.  Reduced injuries because tools are stored in convenient and ergonomic places-workers make less bending, lifting, twisting & stretching.

4.  Increase productivity because it is clear when objects are indeed unavailable.

5.  Easier For any kind of cleanup.

 Written By:
Md. Farid Ahmed
IE Officer
Fakir Apparels Ltd.
BSCIC Industrial Area, Enayet Nagar,
Fatulla,Narayangonj, Bangladesh.
Mobile: 8801814220987
E-mail: farid.ieconcern@gmail.com