Why 70% of Kaizen Initiatives Fail Without 5S And What Leaders Often Miss 5S and Kaizen is widely recognized as a powerful approach for continuous improvement. Organizations invest time, effort, and resources to launch Kaizen programs—conducting workshops, running improvement events, and encouraging employee ideas. Yet, despite the initial excitement, many [...]
From Chaos to Gemstone: A 5S Transformation in Jewellery Studio A renowned jewellery studio was renowned for its exquisite craftsmanship. However, their workspace resembled a treasure trove gone haywire. Tools lay scattered, materials overflowed, and inspiration seemed lost amidst the clutter. So, we took the challenge to transform it through [...]
Introduction Have you ever considered the transformative impact that implementing 5S principles could have on the mining and mineral processing industries? Despite the inherent challenges of dusty environments and complex operations involving manpower, machinery, and materials, one of our clients—a prominent player in this sector—faced inefficiencies in material management, space [...]
Introduction In the ever-evolving landscape of the manufacturing and processing industry, the quest for precision, safety, and efficiency never ceases. This case study unveils the remarkable journey of a manufacturing industry’s instrumentation workshop that harnessed the power of the workplace excellence methodology to not only optimize its layout but also [...]
This is a very famous case study of Ford transmission system vs Japanese transmission system. Both were manufactured as per drawing. But the difference was in the consistency. Japanese parts consistency was much higher. They were not just matching drawing specifications. But were very close to each other. Which means [...]
5. No FPP (Fixed Point Photography) “You have to know the past to know the future – Carl Sagan” Taking before picture of your 5S activity is like keeping history of what was happening. Before you jump to 1S, 2S, 3S…… wait. Take time and capture current state in photographs. [...]
4. Not keeping log of Red Tag items “You can’t manage what you don’t track – Valentino Crawford” In a large government utility once after doing a massive 5S campaign and removing a lot of items in 1s (Red Tag), the top management was reviewing the status. Suddenly a senior [...]
3. Not deciding time for action on Red Tag “Removing a Red Tag is more important than putting a Red Tag.” Usually the top management that starts 5S activity is not aware that the during the 1s (Seiri) activity, they would have to take timely decision on many items (especially [...]
2. Not putting Red Tag and doing 1S activity. “It is like entering a hall without a ticket.” Many times organizations are in hurry to do 5S (I don’t know why?). So they just identify iterms that are not required in a perticular area and put it in Red Zone [...]
1. Not doing why-why analysis after 1S activity “Putting “Red Tag” and keeping the items in Red Zone is not enough” In a large machine manufacturing company when we did Red Tag campaign, we found more than 2178 tags. But we just did not stop at putting those Red Tag [...]
