5s Implementation

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A 5s Implementation Plan
For The Shipping Department at Helical Products Co.
By Eric William Walker

A Senior Project submitted
In partial fulfillment of the requirements for the degree of Bachelor of Science in Industrial Engineering

California Polytechnic State University
San Luis Obispo

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Date of Submission:

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EXECUTIVE SUMMARY
Helical Products Company is a business that manufactures flexure products, such as couplings and u-joints. As part of a movement towards lean manufacturing, Helical Products Company of Santa Maria, California is need of a principle that will help them continuously improve their shipping department. A study of 5S, a lean principle focused on waste reduction, will be done to investigate opportunity for implementation. A literature review takes a peek on research of lean manufacturing history, lean workbook/ tutorials and lastly case studies and journal articles. The output of research provides a design plan for Helical using 5S and other lean principles compatible with 5S, such as error proofing and Value Stream Mapping. A list of suggestions based on analysis and feedback from the Helical shipping department is provided. Lastly, a 5S manual catered for Helical Products Company is attached in the appendix.

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TABLE OF CONTENTS
Executive Summary....................................................................................................................................... 1 Introduction .................................................................................................................................................. 3 Literature Review .......................................................................................................................................... 5 5S Implementation Plan Design .................................................................................................................. 12 Current State .......................................................................................................................................... 12 Evaluation of the Current State .............................................................................................................. 12 Visual Inspection of Shipping Department ............................................................................................. 14 5S Steps for Implementation .................................................................................................................. 16 Suggestions and Recommendations for Future State ................................................................................ 17 Future State VSM Analysis ...................................................................................................................... 17 Barcode Scanner for Sage Mas-500 System ........................................................................................... 19 Packing Peanut Hopper (Overhead Dispenser) ...................................................................................... 20 The Cost of 5S ......................................................................................................................................... 21 Conclusion ................................................................................................................................................... 22 Index of Tables and Figures ........................................................................................................................ 23 Appendix 1: 5S Suggestion Box Explanation ............................................................................................... 24 Appendix B: 5S Manual For Helical ............................................................................................................. 25 Bibliography...
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