Setup time reduction through 5-S implementation in Indian small scale multiproduct manufacturing industry: A case study Ajay Anantrao Joshi M. Tech Student, Department of Industrial Engineering RCOEM, Nagpur, India ajayjoshideoli@gmail.com Dr. V. S. Deshpande Professor, Department of Industrial Engineering RCOEM, Nagpur, India deshpandevs@rknec.edu Abstract - Profitability is one of the major KPI of any organization. Manufacturing lead time (MLT) is the total time required to manufacture a product from order to delivery. Reduction in the MLT reduces downtime and improves uptime that will improve productivity, customer network and profitability. The majority part of lead time includes setup, processing and inventory time. The case industry has longer setup time for all product categories. The longer setup time is due to longer searching time approximately 60-70%. The setup time can be reduced through the reduction of searching time. 5-S a lean manufacturing tool is selected for the reduction of setup time through reduction of searching time. Lean manufacturing is a set of tools intended to reduce non value adding activities within an organization. 5-S is a powerful lean tool that organizes workplace to reduce searching time & inventory time. It consequently reduces setup and lead time which directly reflected as an improvement in the organizational performance. 5-S principle is consists of five steps, organization, neatness, cleaning, standardization and discipline, found helpful for quality and productivity improvement. Successful 5-S implementation in the case industry shows that average of 6% reduction in setup time for all products categories. Keywords—Setup time reduction, 5-S, Lead time reduction, Small scale mutiproduct manufacturing industries. I. INTRODUCTION: "One of the most noteworthy accomplishments in keeping the price of products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost." (Henry Ford, 1926) A. Introduction to 5-S Principle: 5-S is a systemized and methodical approach allowing teams to organize their workplace in the safest and most efficient manner. 5-S practice is well recognized methodology used by the Japanese for improving the work environment. It consists of five steps, organization, neatness, cleaning, standardization and discipline, found helpful for quality and productivity improvement. 5-S practice is useful because it helps everyone in the organization to live better life. (Ho, 1999) Takashi Osada developed the original concept of 5-S in the early 1980s. He coined the concept as the five principles to a total quality environment. These concepts are totally applicable to any workplace. The practice of the 5-S principles is not only useful for the workplace but also helps them personally by improving their thinking process. (Kem Ramdass, 2015) B. 5-S Approaches: 5-S approach is a procedure for the implementation of 5-S in the organization. The following table shows the comparison between Takashi Osada’s approach and Hirano’s approach. Osada concentrate on continuous training to make 5-S as a culture in the organization. TABLE I 5-S APPROACHES (KEM RAMDASS, 2015) 5-S Phase Takashi Osada (1996) Hirano (1991) Seiri Organization: To organize things in order for ease of use and removing unnecessary items. Organization: Eliminate unneeded items. Seiton Neatness: Everything in its place, a place for everything. Orderliness: Enables easy retrieval Seiso Cleaning: Create a faultless environment through cleanliness. Cleanliness: Keep everything clean and neat. Sieketsu Standardization: Continuous improvement through organization neatness and cleaning. Standardization cleans up: Make the 5-S part of the organization. Shitsuke Training or discipline: Imbibe the principles of 5-S through continuous training and development. Discipline: Form a habit through procedures. II. LITERATURE REVIEW Siddarth Srinivasan et al (2016) have mentioned the importance of safety at workplace and how lean tools (mostly 5-S) can help to reduce the safety issues. Author has prepared and conducted a Safety Climate (SCAT) questionnaire survey to measure the organizational performance. The results shows that cycle time has reduced by 16.6%, floor space utilization decreased by 18.2% and inventory held up reduced by 36.6%. Joshi A. A. (2015) has discussed 5-S implementation strategy and outcomes in detailed. Author has introduced safety and spirit (team spirit) as a sixth and seventh principle. Author has mentioned that the searching and setup time can be reduced by implementation of 5-S principles. Kem Ramdass (2015) has discussed the problem of waste management that was faced by textile industry and provide 5-S methodology to solve the problem. Author has developed cause and effect relationship for the problem and found that 5-S can be implemented to resolve the problem. 5-S implementation result shows that approximately 80% cost has saved. R. S. Agrahari et al (2015) have explained the 5-S implementation methodology and guidelines to improve performance of the International Conference on Advances in Mechanical Engineering (ICAME-16), 3-4 June 2016, GHRCE, Nagpur ISBN: 978-93-5265-488-8 92