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From ORE to OUTPUT: Enhancing Efficiency through 5S Principles in Mining & Mineral Processing Industry

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 utilization, and procurement processes. These challenges resulted in increased costs and operational hurdles. However, by embracing 5S principles, significant improvements were achieved, leading to enhanced efficiency, cost savings, and streamlined operations. By implementing the 5S methodology, we initiated a comprehensive overhaul of organizational processes, focusing on Sort, Set in Order, Shine, Standardize, and Sustain.

Actions Taken

We initiated the 5S Program at our client’s site, prioritizing the awareness of workplace significance in individuals’ lives. All employees received training on the initial three steps of Seiri (Sort), Seiton (Set in Order), and Seiso (Shine), complemented by hands-on experience. Subsequently, we implemented the proven step-by-step methodology of 5S, reinforced by a periodic review and auditing system, which yielded remarkable results in the mining industry segment.

Key Actions & Their Results

  • During the Sorting phase, the client identified unwanted items valued at Rs. 25 Lacs, which were subsequently scrapped
  • Identified and repurposed non-moving material worth INR 18 Lacs, optimizing resource allocation
  • Created over 500 Sq. Mtr. of additional space by removing unwanted clutter resulted in reducing space constraints, reducing congestion and improving workflow
  • Reduced material and document searching time by 70%, enhancing operational efficiency
  • Streamlined stationery procurement, reducing costs by 80% and simplifying the stationery management (requirement release to stationery item receipt) process by 65%
  • Reduced excess inventory of diesel, grease, various grades of oil, and packaging bags by 30%
  • Addressed unsafe plant situations, prioritizing employee well-being and fostering a safer work environment through effective mitigation measures

Conclusion

    Through the strategic implementation of 5S principles, our client achieved remarkable improvements in cost-effectiveness, efficiency, and safety. This case study underscores the transformative power of 5S in driving operational excellence and positioning mining and mineral processing industries for sustained success.

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