Full Length Research Paper
5S activities and its application at a sample company
Derya Sevim Korkut1*, Nevzat Cakıcıer1, E.Seda Erdinler2, Göksel Ulay3 and Ahmet Muhlis Do an4 1
Duzce University, Faculty of Forestry, Department of Forest Industrial Engineering, Duzce, 81620, Turkey. 2 Istanbul University, Faculty of Forestry, Department of Forest Industrial Engineering, Istanbul, Turkey. 3 CAD Engineer, Numarine Yacht Company, Istanbul, Turkey. 4 Forest Industry Engineer, Duzce, Turkey. Accepted 27 February, 2009
Total Productive Maintenance (TPM) targets enabling the machine operators to undertake the maintenance activities and therefore to increase the efficiency of the equipments. It struggles with six great losses decreasing the efficiency of the equipment. 5S, which is the pre-step of TPM, is a systematic approach providing the contribution of all personnel in the cleaning regime of the company. The clean and steady environment targeted by 5S has positive impacts on the work safety, quality, efficiency and morale. In this study, 5S system, used for ensuring order and discipline in the companies and ensuring the supervision of both simple and even the smallest details, has been reviewed in full details and they have been taken under the content of the research through selecting the assembly department as pilot department for 5S activities applied at a yacht manufacturing company. It has been targeted to set this as a guide for the directors of the company and the researches working in this field by assessing the results of this study. Key words: 5S, TPM, activity, company. INTRODUCTION Total Productive Maintenance (TPM) is a protective maintenance system requiring the participation of all departments in order to obtain maximum equipment efficiency in an organization, which involves all human resources. It is defined as the integrity of effective maintenance and autonomous maintenance activities conducted by all personnel as in small group activities (Jeong and Philips, 2001; Brah and Chong, 2004). TPM is a management system and includes “Total” term, total economic efficiency and profitability as well as total planned maintenance and participation. The main target of TPM; is to drop six great equipment losses (equipment defect losses, equipment preparation and adjustment losses, small stops and idle operation losses, speed losses, quality defects and reprocessing losses, product losses and initial losses) to zero or to the lowest level and to provide the increase of product quality and equipment efficiency. The business target; can be listed as worldwide success, customer satisfaction, competition power and increasing market share (Nakajima, 1988). In order to provide the machine equipment efficiency, initially the application of 5S should be encouraged. At the companies applying 5S, the presence of unnecessary equipment around the company is avoided and more effective utilization of the operation area is provided. More productivity is obtained from the old workbenches, better maintenance is done and as a result, the performance of the company improves. TPM is a system revealing itself as of the beginning of the application. The most important reason of this is the 5S applications. Through the proper application of 5S activities, a visible change occurs within the factory. Since it is executed in order to use the factory’s area and the equipments in a more efficient manner, it improves the efficiency of the company (Sevim, 2005). Through the first three principles,5S approach prepares the environment conditions minimizing the work flow and through the last two principles, it targets the protection and development of the revealed improvement.
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