ISSN(Online) : 2319 - 8753 ISSN (Print) : 2347 - 6710 International Journal of Innovative Research in Science, Engineering and Technology (An ISO 3297: 2007 Certified Organization) Vol. 4, Issue 3, March 2015 Copyright to IJIRSET DOI: 10.15680/IJIRSET.2015.0403063 1103 Process Flow Improvement through 5S, Kaizen and Visualization Mayank Dev Singh 1 , Swati Singh 2 , Abhishek Chokshi 3 , Harshad Chavan 4 , Dhrudipsinh Dabhi 5 Assistant Professor, Department of Mechanical Engineering, SIE College, Vadodara, Gujarat, India 1, 2 U.G. Student, Department of Mechanical Engineering, SIE College, Vadodara, Gujarat, India 3,4,5 ABSTRACT: Nowadays, manufacturing industries throughout the world are interested in lean manufacturing philosophy. This project is based on lean manufacturing tools like 5S, Kaizen and Visualization. 5S is tool to ensuring systematic organizational environment, Kaizen is continuous improvement through small steps to obtain economical result of the organization and Visualization is technique of creating images, diagra ms or animations of firm‟s activity which are helpful and effective way of communication for all people connected with firm. This project is intended to utilize these tools and come up with integrated approach. Also to reduce abnormality in organization by applying ergonomics for various working positions of employees which improve the productivity, by applying it at pipe manufacturing industry “Sandvik Asia Pvt. Ltd, Mehsana, Gujarat”. Owner of firm is also interested to implement this concept; hence as an industrial perspective this project will give us knowledge that how the practical implementations of lean concepts takes place. KEYWORDS: 5S, Kaizen, Visualization, Abnormality, Ergonomic. I. INTRODUCTION Nowadays, manufacturing industries throughout the world are interested in Profit Maximization with maintaining quality to stay in competitive market. At the present time of a highly competitive market, to improve productivity with best quality and to improve market share at least cost, it is necessary to develop, improve and sustain systematic and healthy organizational place. At present scenario the industry Sandvik Asia Pvt. Ltd. is facing various types of problem due to unadapted standards and techniques. There is large scope to implement lean tools to work on these problems. This project is based on application of lean manufacturing tools like 5S, Kaizen and Visualization. The company, Sandvik Asia Pvt. Ltd., is interested to apply these tools at their place. This project also aims to reduce abnormality in organization by applying ergonomics for various working positions of employees. As an industrial perspective, this project intimates practical implementation of lean concepts.  Objective of the project research  To improve efficiency of the Plant by using various industrial engineering techniques.  To apply tools of lean manufacturing (5S, Kaizen, Visualization).  To apply ergonomics for various working positions of employees.  To reduce abnormality in organization. II. LITERATURE REVIEW Desai et al. (2012) worked on “Total Productive Maintenance (TPM) Implementation in a Machine Shop: A Case Study”. According to them the goal of any TPM program is to improve productivity and quality along with increased employee morale and job satisfaction. In today‟s industrial scenario huge losses/wastage occur in the manufacturing shop floor. This waste is due to operators, maintenance personal, process, tooling problems and non-availability of components in time etc. Other forms of waste includes idle machines, idle manpower, break down machine, rejected parts etc. are all examples of waste. They concluded that, the experience of implementing Total Productive Maintenance is shared and investigated for a company manufacturing automotive component. Concept is implemented in the machine shop having CNC turning centres of different capacity. Overall Equipment Effectiveness is used as the