Our 5S Journey: From the Shop Floor to NCQC India 2025

In this article, I will share our 5S journey, the improvements we implemented on the shop floor, and our experience of taking these activities to NCQC India 2025.

Before implementing 1S, we prepared a 5S layout for our department and divided it into 22 designated areas. Our 5S implementation area was identified as the Hydraulic Service Room. A 5S team was formed, and our organization provided 5S training to improve our understanding of the concept. Our 5S organizational structure consisted of the Zonal Head, 5S Zonal In-charge, 5S Area Leader, and 5S Area Members. After completing the initial preparations, we started implementing 5S in our area. Before beginning the activities, we took photographs of the Hydraulic Service Room

Initial Photos

We also trained our technicians on the 5S concepts. 5S Pledge taken everyday to make it a habit ..

Implementation of 1st S -SORT

We identified, classified, and removed all unnecessary materials from our hydraulic service room, retaining only the items required for our day-to-day activities. Red tags were used to identify unnecessary materials, which were then handed over to the stores. Through this Sort activity, we created additional space and established a clear classification of materials within our department.

After removing the unwanted materials from our Hydraulic Service Room, we identified around 21 red-tagged items. These materials were tagged and stored in a separate designated area.

Our organization also maintains a Red Tag Portal where we enter the details and specifications of the tagged materials. If anyone within our plant requires any of these items, they can check the portal to find the material details and easily contact the concerned person.

Benefits from SORT

S.No	Criteria	Units		Status
			Before	After	Benefits
1	Space saving in hydraulic room	Sq.Ft	100	250	150
2	Red tag material collected	Nos	21	2	19
3	Elimination of unsafe condition	Nos / Occasion	0	1	1
4	Usage of vertical space	Sq.Ft	50	150	100

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Implementation of 2nd S – SET IN ORDER

We ensured that every item had a designated place and was maintained in its proper location. Each necessary item was clearly identified to enable easy access and retrieval. We established a systematic identification and storage method so that anyone could quickly locate, use, and return materials to their designated places. To support this, we implemented colour coding, numbering, labelling, and zoning across our hydraulic service room

Benefits from SET IN ORDER

S.No	Criteria	Units			Benefits
			Before	After
1	Retrieval time of O rings	Minutes	20	1	19
2	Retrieval time of tools from tools cup board	Minutes	5	0.5	4.5
3	Retrieval time of couplings & valves	Minutes	10	1	9
4	Retrieval time of nipples & fittings	Minutes	10	1	9
5	Retrieval time of hoses	Minutes	10	1	9
6	Retrieval time of seals	Minutes	20	1	19
7	Retrieval time of cylinders	Minutes	10	1	9

Implementation of 3rd S – SHINE

We identified and eliminated sources of dirt, addressed difficult-to-clean areas, and rectified deteriorated parts to maintain workplace cleanliness. We ensured that all equipment and materials were kept clean and in good condition, ready for use at all times.

Benefits from SHINE

S.No	Criteria	Units			Benefits
			Before	After
1	Reduction of hydraulic room cleaning time	Mins	60	30	30
2	Rain water entering stoppage	No of locations	4	0	4
3	Reduction of cylinder failure	Cylinder failure / Year	4	0	4
5	Reduction of hose failure	Hose damage/Year	2	0	2
6	No of lighting arrangement	Nos	3	6	3

Implementation of 4th S – STANDARDIZE

We standardized the implementation of the first three S’s (Sort, Set in Order, and Shine) across our hydraulic service room. We developed standard operating procedures (SOPs), displayed 5S and safety signs, implemented a standard colour-coding system, and established designated zones for storing and parking equipment.

We use the 5S guidelines maintained in our organization’s IMS Portal for easy access to standardized procedures and implementation of 5S across all other areas in our Plant.

Audit System

5S implementation is monitored through Management Audits conducted by senior management, 5S Cross-Functional Team (CFT) Audits, and 5S Zonal In-charge Audits. The 5S incentive audit is jointly conducted by 5S Champions and the Business Excellence (BE) team for selected areas. Team members are eligible for 5S incentives if the overall audit score is 85% or above, with a weightage of 20% for the 5S Champions’ audit, 20% for the BE team audit, and 60% for the CFT audit.

We then initiated a 5S self-audit system in our department and achieved a score of 92 out of 100 in September 2024.

During the same month, we scored 90 out of 100 in the CFT audit. We reviewed the remarks for the areas where marks were reduced and submitted PDCA fixed-point photographs as evidence of the corrective actions taken. We have continued this practice for every audit remarks.

Benefits from STANDARDIZE

S.No	Criteria	Units	Status
			Before	After	Benefits
1	Reduction of hose failures (Heat applications)	Nos	8	2	6
2	Reduction of spare cylinder testing time	Mins	30	20	10
3	Reduction of stamping side wall cylinder service time	Mins	120	90	30
4	Reduction of plate charging structure lifting cylinder service time	Mins	300	240	60

Implementation of 5th S – SUSTAIN

We sustained 1S–5S practices through discipline, commitment, and employee involvement. We conducted awareness and refresher training, followed a daily 5S pledge, and carried out regular cross-functional 5S audits. We encouraged participation through 5S displays, recognition, and awards for housekeeping improvements. Monthly best practices were selected and rewarded.

By implementing 5S in our hydraulic room, we improved equipment maintainability and reduced Mean Time to Repair (MTTR).

IMPROVEMENT IN MTTR
Sl.No.	EQUIPMENTS	Target	Before MTTR (Hours)	After MTTR (Hours)
1	Stamping Station-I	1.50	3	2
2	Stamping Station-II	1.50	2.05	1.00
3	Pusher Car-I	1.50	2	1
4	Pusher Car – II	1.50	1.5	0.5
5	Quench Car	1.50	3.03	1.50
MTTR (Mean Time to repair)=Sum of time for repair / No.of repair

The Inventory reduced in hydraulic Spares

Benefits from SUSTAIN

S.No	Criteria	Units	Status
			Before	After	Benefits
1	No of SOPs revision – hydraulic room 5s	Nos	8	16	8
2	No of Kaizen	Nos	4	11	7
3	Employee morale improved	Nos		Intangible benefits

Achieved Gold Award in the 5S Internal Convention 2025, recognizing best adherence to 5S principles

Every year, our organization conducts an internal 5S convention. On May 24, 2025, all departments in our plant participated in the convention, with a total of 15 teams taking part. Our team also participated and received the Gold Award.

In June 2025, our team participated in the 11th NCQC competition at the Madurai Chapter, held at KLN College of Engineering. We presented our 5S implementation and won the Par Excellence Award. The team members are Mr. Mohan, Mr. Kandhaguru, Mr. Mani, and Mr. Loganathan.

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