5S WORKPLACE ORGANIZATION

5S Is one of the most widely adopted

techniques from the lean manufacturing Toolbox. Along
with standard work and total productive
maintenance, 5s is Considered a“foundational”lean
concept, as it establishes the operational stability
Required for making and sustaining continuous
improvements. The primary Objective of 5s is to
create a clean, orderly environment- an environment
where There is a place for everything and everything is
in its place. Beyond this , many Companies begin
their lean transformation with 5s because it exposes
some of the most visible examples of waste it also
helps establish the framework and Discipline
required to successfully pursue continuous
improvement initiatives
Methodolo
5S

gy

Start S1-Sort S2-Shine

S3
Set in
order
S5-Sustain S4-Standardize

 Mistakes from employees and suppliers.

 Reduce non-value adding activity.
 Reduce time from employee orientation and
training.
 Reduce parts stored in inventory, and associated
inventory carrying costs.
 Reduce unnecessary human motion and
transportation of goods.
 Reduce search time in navigating the facility and
locating tools, parts and supplies.
 Improve floor space utilization.
 Improve employee safety and mortal
 Improve product quality
 VISUAL WORKPLACE
Visual Workplace – also known as visual
factory or Visual management – is a concept .That
emphasizes putting critical information at the point of
need. Visual devices are critical. To moving from
traditional manufacturing to lean manufacturing. In
fact, visual worksplace . Serves as the key sustaining
force in these initiatives , because it ensures that lean
improvements remain clearly visible, readily
understood, and consistently adhered to long after the
kaizen event is over. Visual workplace and 5s go hand
in hand. One of the main purposes of 5s is to prepare
the work environment to hold visual information. From
that perspective, 5s Is a method, while creating a
visual workplace is the goal.

The effective implementation of visual systems

has been documented to generate the Following
dramatic improvements;

15% increase in throughput

70% cut in materials handling
60% decrease in floor space
80% decrease in flow distance
68% reduction in rack storage
45% decrease in number of fork lifts
12% decrease in engineering cycle time
50% decrease in annual physical inventory time
96% decrease in defects

5s workplace organisation

A clean uncluttered&

Well organised workplace

 S1-SORT
Sort refers to the practice of going through all the
tools, materials, etc. In the work areas and keeping
only essential items. Everything else is either stored
Offsite or discarded. This leads to fewer hazards and
less clutter. The goal is to Eliminiate nonessential
items from the workplace. Items are “red tagged and
stored In a local red tag area for a specific period of
time, typically five days. If not re-Claimed by the work
group, items are then moved to one of the company’
central Red tag areas. Here everyone can sift
through the items to see if there is anything They
need. When items have been in the central area for a
specific period of time, The company disposes of them
through resale, donation, recycling, or trash.

In order to implement S1-Sort, there are

action steps that need to be
Taken in order guarantee success.

 Select a 5S application area and take “before”

pictures.
 Review sorting criteria- recommended criteria
are frequency of use, criticality,
And quantity needed for production.
 Create a red tag area- mark off a corner or
space to identify it as the local area
 Tag, record, and move items to the red tag area-
keep records so that the com-
Pany can track assets.
 Take “after” pictures of the uncluttered work
area and red tag area.

Definition– sort target Target outcome an

outcome eliminate uncluttered
Nonessential items from Workplace
workplace
Action steps Resources
1. Identify a 5S- project 1. Red tags
area and 2. Red tag record
Take “before” forms
pictures. 3. Camera for “before”
2. Review sorting and
criteria. “after” pictures
3. Create a local red some companies
tag area. create a central
4. Tag, record, and Storage area for 5s
move red supplies
Tagged items And designate a 5s
5. Take “after” coordinator
pictures. To manage supply
6. Move tagged items stock.
to red
Tag area.
 S2 – SHINE
The S2-Shine step includes three primary activities
which include getting the
Workplace clean, maintaining its appearance, and
using preventative measures to
Keep it clean. Shine the workplace by eliminating dirt,
dust, fluids, and other debris.
Each team member should be equipped with
adequate cleaning supplies that have
Been tested to make sure the solution will not harm
any equipment or work areas.
Teams can clean things such as equipment, tools, work
surfaces, desks,storage areas
Floors, lighting, and anything else that affects overall
cleanliness. A team may also
Paint or coat work surfaces, equipment, floors, and
walls. Treat cleaning as an insp ection process. Use it
to identify even tiny abnormal and pre-failure
conditions.
Working in clean environment enables workers to
notice malfunctions in equipment
Such as leaks, vibrations, breakages, and
misalignments. The shine process should
Not be left for a special janitorial crew. In order to
make sure everyone participates
And works together, each team should establish regular
schedule for routine cleaning
As well as deep cleaning.

Once the work area, tools, and

equipment are clean, they need to be kept that Way.
Continued housekeeping is one – way to keep the
work area clean, but the
Better method is to prevent things from getting dirty
in the first place. find ways to
Keep the workplace clean by eliminating sources of
contamination. Equipment that
Is kept clean performs more efficiently, has less
unscheduled downtime,and reduces
Costs to the company. Many organizations find that
safety and productivity improve
As regular maintenance and housekeeping become the
norm.

Follow these action steps to guarantee

success.
 Define “clean” – you may face conflicting
definitions for clean within your work Area. Find
a definition that everyone supports.
 Get cleaning supplies – be sure to identify
appropriate cleaning supplies for your Work
area. Some cleaning solutions may harm
equipment while other Cleaning instruments
may harm metals, photo cells, or
tooling.Consult sanitation Specialists for
guidance.
 Take “before” pictures – a record of your
current state often generates the Motivation
to keep things clean.
 Clean the work area – share the work load
among the group.
 Eliminate small imperfections through cleaning
and inspecting activity.
 Take “ after” pictures – use photographs to
demonstrate your results.

JOB AID – SHINE

Definition – shine Target outcome a

remove dirt and clean workplace –
Debris, inspect One that shines, and
equipment and that minimizes
eliminate sources of Sources of
contamination. contamination.
Action steps Resources
1. Define “ clean”. 1.Cleaning supplies
2. Get cleaning such as brooms,
supplies. dust pans, rags,
3. Take “before” degreasers, and
pictures. floor cleaner.
4. Clean the work 2.Personal protective
area. equipment
5. Fix small Such as gloves and
imperfections. eye protection. Do
6. Identify not wear jewellery
contamination that can get caught
sources. in the equipment.
7. Take “after”
pictures.
 S3 – SET IN ORDER

Planning
phase

In S3 – set in order, team members come

together and share the insights they Have gained
during S1 and S2. They analyze the work area for
additional improvement Opportunities and look for
ways to reduce sources of waste and error as well as to
make The workplace more visually instructive. The
team brainstorms potential solutions, with Special
emphasis on using visual resources to achieve
improvements. Be sure to get Feedback and approval
from stakeholders (production, maintenance, etc.)
before making Changes. Use the focus points below
to guide efforts to redesign the workplace for
Improved performance.

Facilities / equipment / tools: Focus is on

organizing and labeling facilities and Equipment.
 Make sure utility pipes,conduits,compressed air
hoses gas cylinders and electrical
Systems are clearly named and labeled to
simplify line tracing.
 Operator tools should be kept near the point of
use, organized and labeled.
 Gauges and indicators should be marked so
abnormalities can be detected at a Glance.
Safety: Focus is on altering people to potentially
hazardous situations and controlling Actions to
prevent an unsafe condition.
 Provide hazard warnings and safe work
instructions at the point of need.
  Make sure that locations for lock out/tag out
devices, eye wash stations, first aid
Stations, and safety showers, etc. are clearly
marked.
 Ensure that the proper personal protection
equipment easy to access and ready For use.

Procedures: Focus is on employee’s ability

to execute job responsibilities within a Given
workplace.
 Make certain that the latest version of work
instructions and job aid are posted.
 Employ visual or auditory signals that alert
operators to abnormal conditions.
 Use mistake – proofing devices to prevent
human and machine errors.
Quality: Focus is on graphically or physically
representing quality standards
 Quality standards should be visually designed
and properly displayed.
 Post examples of acceptable and unacceptable
outputs in a common area.
 Visually display quality performance trends.
Inventory/Material Handling: Focus is on
effective identification of production And
MRO materials, storeroom organization , and Material
movement. Clearly mark:
 Line side inventories (inventory type, max/min
quantity, location, etc.).
 Storerooms (shelf, rack and labels, restocking
indicators, bar – coding, etc.).
 Inventory delivery routes and replenishment
procedures.
JOB AID – SET IN ORDER
 Definition – set in Target outcome a
order evaluate the workplace that is
workplace and add visually instructive
smart workplace and is the source of
Features. minimal waste and
human errors.
Action steps Resources
1. Create a current 1. flip charts for
state workplace creating current and
diagram. future state
2. Team shares insights diagram.
gained during S1 & 2. CAD system
S2. (optional) to draw
3. Evaluate current workplace to scale.
workplace. 3. Camera.
4. Create a future state 4. Stakeholders (i.e.
workplace diagram. production,
5. Get approval for maintenance,
change from safety ) to consider
stakeholders. proposed changes.

S4 – STANDARDIZE
During this phase of implementation, the team
identifies ways to establish The improved workplace
practices as a standard. The goal of standardization is
to Create best practices and to get each team
member to use the established best Practices the
same way.
 Activity
Responsibili
ty
1 Sweep the entire area at the end SREERAG
of the shift.
2 Put away any material that was APARNA
removed from its assigned
storage location.
3 Take empty pallets out of the ANSHITH
area and store in an appropriate
location.
4 Empty garbage’s as needed at ANJANA
the end of every shift
5 Restock materials from overflow ANJALI
area when space permits.
6 Move full pallets to designated VAISHNAVI
areas away from shipping dock.

Rotation Garbage
schedule Sweeping removal
Day Night Day Night
shift shift shift shift
ANJALI APARNA ANJANA
Monday ANSHITH
Tuesday ANJANA APARNA
SREERAG SREERAG
ANJALI ANJALI ANJANA
Wednesday VAISHNAVI
APARNA VAISHNAVI ANSHITH
Thursday VAISHNAVI
Friday ANSHITH APARNA APARNA
SREERAG
In order to standardize, roles and responsibilities
must be clearly and consistently Applied. This can be
accomplished through visual controls such as color
coding , Flow charts, checklists, and labeling to help
reinforce a uniformed approach. Managers And
supervisors need to commit to the initiative in order
to provide guidance, as well As to provide general
support to the team. Team members in return must
embrace 5S Principles and practices in order to help
implement these changes into their work area. As 5S
standards are adopted into each individual work area,
each locale will develop Unique approaches and
methods to accomplishing the specified tasks and
goals. Any Team member working in a specific area
must receive training in that specified Approach
and method of work. Where possible, the tools
used to standardize and Sustain the 5S effort should
be unified across all areas of the plant.

Action steps for implementing S4 –

standardize include

 Brainstorm ideas for making the 5S changes

standard operating procedure.
That may mean updating workplace procedures,
checklists, job aids, diagrams
And the like.
 Make sure all stakeholders are aware of the new
standard – inform and educate.

Definition – Target
standardize outcome
Establish standards to Develop procedures,
maintain 5S checklists, and other
Improvements. mechanisms established
to maintain a work
environment that is
visually instructive, has
minimal waste and
human error, and is
 clean, uncluttered, and
organized.
Action steps Resources
1. Brainstorm ideas for 1.Support from those
making the 5S who can create
changes standard documentation, job
operating procedure. aids, and visual aids.
2. Update 2.Information and
documentation to approval from those
reflect changes. responsible for
3. Make sure all maintaining
stakeholders are company procedures.
aware of the new 3.Poster – making
standard – inform supplies for posting
and educate. new standards in
work areas.
 S5 – SUSTAIN
The purpose of 5S – sustain is to maintain the
momentum generated during the Initial event or
project. A management auditing process should be
put into practice To ensure that employees
understand that maintaining the level of
workplace Organization is a top priority. Management
audits should focus on ensuring that the Routines and
schedules specified in S4 standardize are being
properly maintained. The audit also provides an
excellent opportunity for asking questions and
providing Suggestions that stimulate further
improvements.

Next, the 5S effort needs to be expanded to other

work areas. Use the 5S’ed work Area as a model for
emulation, and invite the original 5S team to share
their ideas And experiences with employees from other
work areas. Be sure to publicize success Stories and
provide appropriate recognition to team members. 5S
newsletters, display And awards are excellent ways
to build employee morale and motivation. Finally, it
Should be reinforced that 5S in an on – going journey.
Workers should be encouraged
To continue to make improvements to their workplace
on a regular basis. The same Work area might
even be scheduled for a follow – up 5S event six
months or a year Later. Continuous improvement
must become part of the routine expectations and
Activities of the work day. When improvement stops,
the likelihood is that workplace Organization will
not just stagnate, but will actually deteriorate. To
avoid that, keep Everyone continually looking for ways
to improve their work conditions.
Action steps for implementing S5 – Sustain
include:

 Audit to ensure that processes established

during S4 – Standardization continue
To be maintained.
 Use the phase 1 work area as a model for other
areas to match, and have the
Original 5S team share their insights and
experiences with employees in other
Work areas.
 Use newsletters, displays and other
communication tools to publicize successes
And reward strong efforts with recognition.
 Evaluate 5S effectiveness and continue to
improve.
 Conduct regular review meetings to identify
additional 5S Opportunities.
 INDUSTRIAL SAFETY
An industrial safety system is a countermeasure
crucial in any hazardous plants such as oil and
gas plants and nuclear plants. They are used to
protect human, industrial plant, and the environment
in case of the process going beyond the allowed
control margins. As the name suggests, these systems
are not intended for controlling the process itself but
rather protection. Process control is performed by
means of process control systems and
is interlocked by the safety systems so that immediate
actions are taken should the process control systems
fail. When it comes to workplace safety, certain
industries must take extra precautions to keep their
workers safe on the job.

Steps for improving the Industrial Safety

1.Create a Safe Work Culture

When employers and their employees all see
safety as a priority, the workplace will
Be safer. The problem is many employers fail to
take the lead to promote a safe work
culture, which can lead to careless attitudes in the
workplace. To create a safe work
culture, employers should lead by example and
celebrate the successes of employees. It’s helpful for
employers to recognize when employees are doing a
good job and practicing
safe work habits. This can keep employees wanting
to do better and better, and such
positive reinforcement goes a long way toward
promoting safety overall.
2. Implement Fall Prevention Systems
Fall prevention systems are essential in many
industries, and the Occupational Safety & Health
Administration has fall prevention regulations that all
companies must adhere to.
It is critical that you find fall prevention equipment that
fits your application. If you need customizable fall
protection, platforms and gates that can al l be
customized and even repurposed to meet the needs of
any application and reduce the risk of fall.
3 .Hire the Right Contractors
A business that hires independent contractors must
take care to ensure that these workers
are practicing safety in the workplace, just like
their own full-time employees. While independent
contractors operate under their own name, your
partnership with them can
also affect your company’s reputation. They are not
your employees and are not required
to have the same core values as your company, but the
contractors you hire should have a good reputation in
their line of work, and it helps to see eye to eye on
the importance of safety.
4.Perform Preventative Maintenance
Conducting regular preventative maintenance on
equipment can significantly reduce the chance of
injuries in many industries. Inspection and
maintenance of your equipment
should be scheduled regularly so that your equipment
is not only safe to use, but its
lifespan is also extended. Regular preventative
maintenance helps you identify potential hazards
before they become a problem, and it will keep your
workers safe from easily preventable accidents on the
job.
5.Encourage Communication
Many workplace accidents occur because employees
fail to speak up or report potential problems. This may
be due to a work culture that does not encourage
employees to communicate effectively with one
another. You can increase communication in the
workplace by holding regular meetings that give
employees the chance to speak their
Mind and make improvements within the
business. Encouraging employees to
Communicate about potential problems can help
make the workplace safer by reducing potential
hazards.
6.Keep the Workplace Clean
It may seem obvious, but many places have cluttered
worksites that can spell disaster for companies —
especially those in dangerous industries like
manufacturing or construction. Reduce the risk of
falls and trips by making sure your employees see the
importance of keeping their work areas clean and free
of debris. By emphasizing that it is for their own
safety, employees may be more willing to keep their
areas mess-free.
7.Don’t Choose Budget Over Safety

Unfortunately, one of the first things to be cut when

reducing a budget is safety training or key safety
systems. While it may seem as though your
business is saving money by removing safety training,
it could instead be costing you more over time.
Employees who
are not sufficiently trained are more susceptible to
accidents, which could put them out of work for good
and force employers to find replacements.
 COMMUNITY ORIENTED PROJECT
ZEBRA LINE CROSSING SYSTEM
Road accidents are increased in recent times. There is many
accidents while crossing the zebra line especially in night times
drivers could not see the persons crossing the zebra lines.
Through our project ZEBRA LINE CROSSING HELPING SYSTEM
we can reduce the chance of accidents

The system helpful for both drivers and walkers and reduce the
traffic block. There is a switch is provided when the switch is
pressed the green light is shined at the side of zebra line after 5
second the green light is turned into yellow and after 5 second
red light is shined instead of yellow. Now the walkers can
safely cross the road. 15 seconds is provided to the walkers to
cross the road. When the given time is expired a critical sound
is produced .After given time the sensor checking there is any
person in zebra line , if there is any person the red light
continue shining , else the green light is shined

There is limit to press the switch, once switch is pressed

after 3 minutes it will work. In emergency situation there is
another button provided .It is very helpful for many
situations .when the emergency switch is pressed the camera
will take photos of the person who pressed the switch . It is
helping to prevent the miss use of emergency button .
PART 2

Mini Project
 ABSTRACT

Women safety is a very important issue due to rising crimes

against woman these days.To help resole in this issue we propose a
GSM based woman safety system.this device consist of a security
system,In case of a woman is harassed or she things she is in
trouble.This system can be turned on by woman in case she even
things she would be in trouble.It is useful because once an incident
occurs with a woman she may or may not get the chance to press the
emergency button.In a button alerting system,in case a woman is hit
on the head behind,she may never get a chance to press panic button
and no one will know she is in trouble.
Our system solves this problem.This device is to be turned on in
advance by a woman in case she is walking on a lonely road or some
dark alley or remote area.Only the woman authenticated to the
devices can start the system by pressing a button.once started the
devices requires the women to press the button.When the button is
pressed the authorized personal number through SMS message as a
security measure,So that nearby people may realize the situation.in
this case even is someone hits the women or the woman falls down
and get unconscious, at the moment of falling the woman can press
the button.The device will prove to be very useful in saving lives as
well as preventing atrocities against women.
The device uses GSM modem along with a arduino based circuit to
achieve the system.
 WORKING PRINCIPLE
This mobile phone detector can sense the presence of an
activated mobile phone from a distance of four to five metres. So it
can come handy in an examination hall or meetings where mobile
phones are not permitted. The circuit can detect incoming and
outgoing calls, SMSes, Internet and video transmissions even if a
mobile phone is kept in silent mode. When it detects an RF signal
from an activated mobile phone, its LED starts blinking and continues
to blink until the signal stops. When a mobile phone is active, it
radiates RF signal that passes through nearby space. The signal
contains electromagnetic RF radiation from the phone.
Capacitor C1 is used in the circuit to detect the RF signal
from the mobile phone. When the mobile phone radiates energy in the
form of RF signal, C1 absorbs it and passes on to the inputs of IC1.
This is indicated by the flashing of LED1. Preset VR1 (2.2M) is used
to vary the range of the circuit. Transistor T1 is used to amplify the
signal obtained at pin 1 of IC1.
CIRCUIT DIAGRAM
 ESTIMATION OF COMPONENTS

SL COMPONENT COMPONENT QUANTITY PRICE

NO: NAME VALUE

1 LM358 OP-AMP 1 10
2 TRANSISTOR BC 548 1 2
( npn transistor)
3 LED 5mm 1 1
4 RSISTORS
R1 100KΩ 1 0.50
R2 220 KΩ 1 0.50
R3 1 KΩ 1 0.50
5 VARIABLE 2.2 MΩ( Preset) 1 3
RESISTOR
6 CAPACITOR
C1,C2 1µF/16V (Electrolytic 1 2
Capacitor)
C3 100µF/16V(Electrolytic 1 3
Capacitor)
7 CON 1 2 pin terminal 1 3
connector
8 SWITCH (on/off) 1 10

9 ANTENNA 15cm (single stand wire 1 8

antenna)
10 BATTERY 9V 1 15
TOTAL COST 59.00
 ABOUT THE COMPONENTS
1.ARDUINO NANO
The Arduino Nano is a small, complete, and breadboard-friendly board based on
the ATmega328P (Arduino Nano 3.x). It has more or less the same functionality
of the Arduino Duemilanove, but in a different package. It lacks only a DC
power jack, and works with a Mini-B USB cable instead of a standard one.
 It comes with exactly the same functionality as in Arduino UNO but quite in
small size.
 It comes with an operating voltage of 5V, however, the input voltage can
vary from 7 to 12V.

TRANSISTOR BC548
BC548 is general purpose silicon, NPN, bipolar junction transistor. It is used for
amplification and switching purposes. The current gain may vary between 110
and 800. The maximum DC current gain is 800.
3. LED (light emitting diode)
A diode is a component that only allows electricity to flow one way. Light
emitting diode (LED) differ from regular diode in that when a voltage is
applied, they emit light

4. RESISTOR
Resistors are one of the most common electronic components. A resistor is a
device that limits or resist current
5. CAPACITOR (electrolytic)
The large capacitance of electrolytic capacitors makes them particularly suitable
for passing or bypassing low-frequency signals, and for storing large amounts of
energy. They are widely used for decoupling or noise filtering in power supplies
and DC link circuits for variable-frequency drives, for coupling signals between
amplifier stages, and storing energy as in a flash lamp.

6. VARIABLE RESISTOR (preset)

A preset is a three legged electronic component which can be made to offer
varying resistance in a circuit. The resistance is varied by adjusting the rotary
control over it. The adjustment can be done by using a small screw driver or a
similar tool. The resistance does not vary linearly but rather varies in
exponential or logarithmic manner. Such variable resistors are commonly used
for adjusting sensitivity along with a sensor.
7. CONNECTOR
It is a 2-pin terminal connector.

8. SWITCH
Any general purpose switch can be used. Switch is used as circuit breaker.

9. BATTERY
Here 9v power supply is used in this circuit.
 APPLICATION AND ADVENTAGES

 It can be used in examination hall or meetings where mobile

phone are not permitted
 Restrict mobile phone in jails which helpful for identify the
criminals who communicate with others.
 To identify the mobile usage of the prohibited area.
 CONCLUSION
The circuit of MOBILE PHONE DETECTOR SYSTEM is constructed for
cost of 59.00 rupees and tested the circuit. And verified the output of the circuit.
The MOBILE PHONE DETECTOR SYSTEM circuit is studied.
 REFERENCE

 www.bestengineeringproject.com
 www.google.com
 Text book