A CASE STUDY OF 5S IMPLEMENTATION IN INSPECTION PROCESS

5S is a lean tool which involves workplace organization and is implemented to reduce the searching time of a product. The methodology adopted in this paper is the 5S pillar approach: Seiri, Seiton, Seiso, Seiketsu, Shitsuke to increase the overall efficiency of the process. The result of implementation of each step of the 5S methodology at XYZ Limited is also shown in this paper. The 5S methodology is applied to solve the problems in inspection department of the forging industry producing several crankshafts with the aim to eliminate losses in the company. The existing problem of the company is dealt with is messy tool setting, bad working environment and inefficient process flow. The company cannot meet customer's demand and works inefficiently, because everyone in the company is not used to a clean working environment and all inventory interrupts the process flow; therefore the major objective of this study is to help company not only to rearrange but also reset the working environment and enhance the process flow by using 5S tools. After implementing of 5S in the inspection department the time saving is 39.60% and also certain process wastes are reduced. The inspection department in the workplace became neat and effective.