Using 5S Lean Management Tool to Assess the Impact of Good Housekeeping on Productivity in Manufacturing Processes
Subject Areas : Production Systems
1 - Department of Industrial Engineering and Engineering Management, Beirut Arab University, Beirut, Lebanon
Keywords: 5S, Housekeeping, Lean manufacturing, Manufacturing problems,
Abstract :
Good housekeeping can be considered as a workplace standard developed to create safe and productive work environment. Its implementation is expected to reduce wastes and defects, increase productivity, safety, and workers’ morale. As there is a lack of sufficient evidence to show the positive impact of good housekeeping on production performance and the importance of the role of continuous improvement in manufacturing industries, this paper is aimed to identify the effectiveness of good housekeeping implementation on manufacturing performance. Three different plastic manufacturing factories were considered in this study. Two of them were facing problems in meeting customer delivery due dates and in running their daily operations, whereas the third factory handled well their production system. To assess the effects of the implementation of good housekeeping, the 5S management tool was used to shed the light on the inconsistencies in implementing good housekeeping in different work areas within the factories. The outcomes of this study obtained from a comparative analysis demonstrated the efficient implementation of good housekeeping led to subsequent improvement in productivity of the factory. These outcomes also suggested that 5S is an effective technique that can be used to improve housekeeping, working environmental, and health and safety standards.
[1] Hirano, H. (1995). 5 pillars of the visual workplace. Productivity Press, New York.
[2] Becker, J.E. (2001). Implementing 5S to promote safety & housekeeping. Professional Safety. 46(8), 29-31.
[3] Eckhardt, B. (2001). The 5S housekeeping program aids production. Concrete products, 104(11), 56.
[4] Chin, K.S., & Pun, K.F. (2002). A proposed framework for implementing TQM in Chinese organizations. International Journal of Quality & Reliability Management, 19(3), 272-294.
[5] Ahmed, S., & Hassan, M. (2003). Survey and case investigations on application of quality management tools and techniques in SMIs. International Journal of Quality & Reliability Management, 20(7), 795-826.
[6] Chapman, C.D. (2005). Clean house with lean 5S. Quality Progress, 38, 27-32.
[7] Hough, R. (2008). 5S implementation methodology. Management Services, 52(2), 44-45.
[8] Howell, V.W. (2009). 5S for Success. Ceramic Industry, 159(7), 17-20.
[9] Bayo-Moriones, A., Bello-Pintado, A., & Merino-Díaz de Cerio J. (2010). 5S use in manufacturing plants- contextual factors and impact on operating performance. International Journal of Quality & Reliability Management, 27, 217-230.
[10] Patel, V.C., & Thakkar, H. (2014). Review on Implementation of 5S in Various Organization. Int. Journal of Engineering Research and Applications, 4(3), 774-779.
[11] Sharma R. and Singh J., (2015). Impact of Implementing Japanese 5S Practices on Total Productive Maintenance. International Journal of Current Engineering and Technology. 5(2), p. 818-825.
[12] Gapp, R., Fisher R., & Kobayashi K. (2008). Implementing 5S within a Japanese context: An integrated management system. Management Decision, 46(4), 565-579.
[13] Alva, I., Rojas, J., & Raymundo, C. (2019). Improving Processes Through the Use of the 5S Methodology and Menu Engineering to Reduce Production Costs of a MSE in the Hospitality Sector in the Department of Ancash. In International Conference on Human Interaction and Emerging Technologies (pp. 818-824). Springer, Cham.
[14] Nizam Ab Rahman, M., Khamis, N.K., Zain, R.M., Deros, B.M., & Wan Mahmood W.H. (2010). Implementation of 5S Practices in the Manufacturing Companies: A Case Study. American Journal of Applied Sciences, 7(8), 1182-1189.
[15] Dudek-Burlikowska, M. (2006). Quality research methods as a factor of improvement of preproduction sphere. Journal of Achievements in Materials and Manufacturing Engineering, 18, 435-438.
[16] Ishijima, H., Eliakimu, E., & Mshana, J. M. (2016). The “5S” approach to improve a working environment can reduce waiting time: Findings from hospitals in Northern Tanzania. The TQM Journal, 28(4), 664-680.
[17] Siahaan, F. S., Purba, J., Buwono, A., Ratih, R., & Refendi, H. (2020). The monozukuri concept as the right 5S implementation tool in Jakarta Vocational High Schools. In Journal of Physics: Conference Series, 1469(1), 012129). IOP Publishing.
[18] Jaca, C., Viles, E., Paipa-Galeano, P., Santos, J., & Mateo, R. (2014). Learning 5S principles from Japanese best practitioners: case studies of five manufacturing companies. International Journal of Production Research, 52(15), 4574–4586.
[19] Bin Ashraf, R., Rashid, M., & Rashid, H. (2017). Implementation of 5S Methodology in a Food & Beverage Industry: A Case Study. International Research Journal of Engineering and Technology, 04 (3), 1791-1796.
[20] Ghodrati, A., & Zulkifli, N. (2013). The Impact of 5S Implementation on Industrial Organizations. International Journal of Business and Management Invention, 2(3), 43-49.
[21] Mali, S., & Bhongade, A.S. (2017). Implementation of 5S in Manufacturing Firm to Reduce Delivery Time of a Product. Industrial Engineering Journal, X(9), 37-42.
[22] Omogbai, O., & Salonitis, K. (2017). The implementation of 5S lean tool using system dynamics approach. Procedia cirp, 60, 380-385.
[23] Rizkya, I., Syahputri, K., Sari, R. M., & Siregar, I. (2019, May). 5S implementation in welding workshop–a lean tool in waste minimization. In IOP Conference Series: Materials Science and Engineering, 505(1), 012018. IOP Publishing.
[24] Gupta, S., & Chandna, P. (2020). A case study concerning the 5S lean technique in a scientific equipment manufacturing company. Grey Systems: Theory and Application, 10 (3), 339-357.
[25] Makwana, A. D., & Patange, G. S. (2022). Strategic implementation of 5S and its effect on productivity of plastic machinery manufacturing company. Australian Journal of Mechanical Engineering, 20(1), 111-120.