1. List the 5S and compare to the lean implementation at Duraweld. If there are differences, explain them.
The ‘5S’ principles which originated from Japanese terms of seiri (sort), seiton (set in order), seiso (shine), seiketsu (standardize) and shitsuke (sustain) are used to create efficient, clean and well organised working environment.
Sort – refers to ensuring that each item in a workplace is in its proper place or identified as unnecessary and removed. When “sorting” is well implemented, communication between workers is improved and product quality and productivity are increased
Set in order – The second stage of 5S involves the orderly arrangement of needed items so they are easy to use and accessible for “anyone” to find.
* Overproduction: Are you producing sooner, faster or in greater quantities than the customer is demanding? * Defects: Does the process result in anything that the customer would deem unacceptable? * Inventory: Do you have any raw materials, work-in-progress (WIP) or finished goods that are not having value added to them? * Movement: How much do you move materials, people, equipment and goods within a processing step? * Extra Processing: How much extra work is performed beyond the standard required by the customer?

At Duraweld, the 5S (Sort, Set to order, Shine, Standardize, and Sustain) was the cornerstone that helps the organisation eliminating the waste.

The first step taken by Duraweld was converting a ‘push’ manufacturing flow to a ‘pull’ process by creating a visual management system of Kanban card. The cards indicate what to process, when to process and how much to produce. Not only it reduces over-production but allows better regulation of intermediate stocks in production cycle. Only the required amount is produced in every stage. This process eliminate waste – no work was carried out unnecessarily, machine time is lesser, better utilisation of space in factory.

The use of shadow boards helps to organise the essential tools. Relevant machines and tools were aggregated in cells. Floors were painted in white to assist warning of maintenance issues or detect early wear. Labelling program ensures item/tool used returned to