4.

EVALUATION AND RESULTS Evaluation of any maintenance activity at the plant site involves accessing whether the company had achieved the policy and goals set at the beginning of its implementation and realized the intended benefit. Auditing of the factory serves as a way to recognize the condition at a particular instant and compare it with that at another instant to judge weaknesses and improvements in this activity. Evaluation criteria of 5S at the SSE were set according to the shop floor distribution and condition of contained items at various sections. Two separate audits were for made for comparing the condition of the factory floor before and after the implementation of 5S. Audit items were divided into groups and listed with the proposed below neat, fair, better and excellent conditions for each and corresponding marks were allotted to each condition on a scale of 1-10. Main items of concern are listed in sections 4.1 and 4.2 The marks were then converted to percentage for each S and presented in the form of chart (fig 4.1). A separate evaluation is made for warehouse section (fig 4.2). 4.1. Observation of 3S The 3S (Sort, set in order and shine) were observed by visualizing the following item on the scale of neat and cleanliness, proper placement and arrangement and easy access and availability. Benches & Cupboards arranged clear of unneeded items Parts, Tools & Accessories in order at designated places No obsolete equipment and clear Surrounding Area Reserved Parts & Tools at their allotted locations Material of Packing at identified places with tags No Garbage anywhere and Containers of Garbage having sufficient capacity Chemical and water tanks be covered properly Sources of dirtiness should be cured or contained Hoses and wires secured and placed at proper locations Appropriate Lighting for clear visibility Transportation Equipment should have clean and well-leveled trays. Benches & Cupboards arranged clear of unneeded items Parts, Tools & Accessories in order at designated places No obsolete equipment and clear Surrounding Area Reserved Parts & Tools at their allotted locations Material of Packing at identified places with tags No Garbage anywhere and Containers of Garbage having sufficient capacity Chemical and water tanks be covered properly Sources of dirtiness should be cured or contained Hoses and wires secured and placed at proper locations Appropriate Lighting for clear visibility Transportation Equipment should have clean and well-leveled trays. 4.2. Sustain and Standardize These two were observed on the criteria given below Standards on basis of completion, in logical order and satisfactory use Uniforms and safety equipment Line identification, Markings on the floor Signs board, Visual aids Proper observation of cleaning schedule and its registration Absence of Excess materials/ objects Material inventory level 4.3. Comparison of Results Results of the audits were scored in spread sheet and compared visually by converting the entered data into charts. Two representative charts are given below. Fig. 5.1 show the chart for comparison of percentage observation of each S at the factory floor. It represents an improvement from 30% to 70% in average of observing 5S at the factory floor. Fig. 5.2 depict the chart for improvement in inventory store during the two months of implementation of 5S. According this scale the condition of warehouse is improved to double during this period. Figure 4.1 Comparison of 5S condition at the production hall during audits (this is fig caption) Figure 4.2 comparison of inventory condition during two audits (this is fig caption) 5.4 Evaluation in terms of Benefits Both the tangible as well as the intangible benefits have been assessed. Tangible measures were recorded while auding the factory floor. Data were collected by team members. These are summarized in points below. 1. Trouble free part. 2. Quick problem finding at supplier end.

3. Effective countermeasures of quality problems. 4. Increase product and process quality. 5. On time delivery of parts 6. Ever ready production conditions 7. Develop control through visibility 8. Empower employees to sustain work area. The intangible measures were reported by supervisors, who were requested to observe and access the performance of individual subordinates. These are listed below 1. Reduced machine down time. 2. Work Place improvement at supplier end 3. Simplified work environment 4. To reduce waste hidden in the plant 5. To Raise the quality level of Local Supplier 6. Time Saving of line 7. To Raise the delivery level of Local Suppliers 8. Reduced space requirements and storage costs 9. Reduced machine down time 10. Improve safety