A STUDY ON ORGANIZATIONAL

EXCELLENCE WITH REFERENCE TO

SRI VELA SMELTERS PRIVATE,LIMITED.
PARAMATHIVELUR.

MINI PROJECT WORK

Submitted
By
TA.PRIYANHA
Register No: 1861037
In partial fulfillment for the award of the degree
Of
MASTER OF BUSINESS ADMINISTRATION
In
K.S.R. COLLEGE OF ENGINEERING (Autonomous)
ANNA UNIVERSITY: CHENNAI 600025
TIRUCHENGODE – 637215
OCTOBER 2019
 BONAFIDE CERTIFICATE

Certified that this project report A STUDY ON

ORGANIZATIONAL EXCELLENCE WITH
REFERENCE TO SRI VELA SMELTERS PVT,LTD.
PARAMATHIVELUR, is the bona fide work of
TA.PRIYANHA who carried out the mini project work under my
supervision.

SIGNATURE SIGNATURE
Dr.N.S.SANTHI, MBA, MPhil, Ph.D.,
Dr.T.Vijayalakshmi, MBA,M.Phil,Ph.D.,
HEAD OF THE DEPARTMENT
ASSISTANT PROFESSOR

Submitted for the Project Viva-Voce Examination held on

Internal Examiner External
Examiner
DECLARATION

I affirm that the project work titled A STUDY ON 5S

IMPLEMENTATION IN ANGEL STARCH AND FOOD
PRIVATE LTD, ERODE being submitted in partial
fulfillment for the award of TA.PRIYANHA MBA, is the
original work carried out by me. It has not formed the part of
any other project work submitted for award of any degree or
diploma, either in this or any other University.
 TA.PRIYANHA
Register No:
1861037

I certify that the declaration made above by the candidate is

true.

DR.T.VIJAYALAKSHMI, MBA,
M.PHIL, PH.D.,
ASSISTANT PROFESSOR
DEPARTMENT OF BUSINESS ADMINISTRATION

ACKNOWLEDGEMENT
 I would like place my sincere thanks and gratitude to our
chairman of
K.S.R COLLEGE OF ENGINEERING, Lion
Dr.K.S.RANGASAMY, MJF, for providing me the needed
facilities to do my project work.
I express my sincere thanks to our principal
Dr. P.SENTHILKUMAR., Ph.D., for their support given to
me in carrying out the project work.
I like to express my sincere thanks to our Head of the
Department of the Management studies Dr .N. S. SANTHI.
MBA, M.Phil., Ph.D., the support given to me in carrying out
the project work.
I would like my sincere gratitude to my guide
DR.T.VIJAYALAKSHMI, MBA,M.PHIL,PH.D.,
Assistant professor and the staff members of MBA
department for their valuable guidance, which helped me a lot
to establish control over this project work.
 I like to express my thanks to Mrs. MEENAKSHI of
ANGEL FOODS ERODE for the support and guidance.
I wish to acknowledge my special thanks to my parents,
my friends and other well – wishers who helped me to
complete this project work successfully.

T.A.PRIYANHA
1861037

ABSTRACT

This project represents Food Safety Practices and the

implementation of 5S Workplace Management System in the
Storage Area of Foods Industry; Angel Foods starch Pvt Ltd,
which is known for the manufacturing of Indian traditional
Sweets, Snacks and Foods. The aim was to implement all the
food safety compliances and 5S in the storage area so as to
simplify work processes, maintaining hygiene and safety
standards in the zone. Store is the backbone of every
organization.

It is a place where things like raw material, packaging

material, consumable items and engineering materials are kept
for future use. Food borne illnesses can easily be spread when
employees are not trained in how to receive and store food.

Therefore, it must be kept clean, hazardous free and all

the food materials to be stored in a sanitary manner to prevent
food borne infections and diseases. Post 5S Implementation
not only the store section but the whole organization including
the employees gained both tangible and intangible benefits
like improved hygiene and safety, quality and improved
economy.

Keywords:

5S, Food Safety and Hygiene, Quality, Tangible and

Intangible benefits, 5simplementation, lean manufacturing.
 TABLE OF CONTENT
CHAPTER TITLE PAGE
NO NO
ABSTRACT I

I INTRODUCTION
1.1.Introduction about the study
1.2.Company profile
1.3. Industry Profile.
II REVIEW OF LITERATURE
2.1 literature survey
III DESIGN OF THE STUDY
3.1. Objectives of the study
3.2. Scope of the study
3.3. Limitations of the study
IV FINDINGS:5S AT ANGEL FOOD
STARCH
4.1. lean manufacturing
4.2. Introduction of 5s
V SUGGESTIONS AND
CONCLUSION.

CHAPTER I

INTRODUCTION
1.1 INTRODUCTION ABOUT THE STUDY

One of the most significant developments in recent times

is giving more importance to the Work place organization and
information management. Work place organization is a key to
increase the effectiveness of teams and there by the
organization. Proper planning and management of
Information, ranging from personal data to organizations
details and small information to business prospects is
necessary in the present world. Every action is being recorded
for future references, either in the form of soft copy or hard
copies. Hence there is a need to have a well organised work
place organization methodology in every part of the
organization.
Among all other world class manufacturing technologies
being implemented by various companies across the world 5-
S Housekeeping Index is the most appropriate one which can
be used and implemented successfully in service sector. 5-S is
mainly concerned with creating a well-organised and neat and
clean working environment in the whole working place. In
service sector the implementation of 5-S will help in
enhancing customer satisfaction and also improve the
corporate image among its competitors.
 This dissertation will help in knowing how to implement
5-S in a service sector especially in an educational institute. It
will help in knowing the process which could help in
implementing 5-S and improve the work place and enhance
better environment. This report will help to know and identify
the wastes and also would provide the methods for removing
and limit the wastes in the institute which will also help in
more systematic work procedures in the college. This 5-S
makes all the members in the college to work towards its
principle starting from the dean to even to the cleaning person
and also makes the students follow certain rules which help in
keeping the place in a well organised way.
The 5S’s are a group of techniques which would promote
workplace organization, ensure adherence to standards and
encourage the spirit of continuous improvement.
The“5S”Philosophy once fully implemented, the 5S process
would increase moral, create positive impressions on
customers, and increase efficiency in a well organized way
.Not only will employees feel better about where they work,
the effect on continuous improvement can lead to less waste,
better quality and shorter times of locating.
 Thus the project explains the importance of a well
organised work place in an educational institute and benefits
of 5s that is implemented. This project also helps in creating a
clean and systematic work process in the institute.

1.2 COMPANY PROFILE

ANGEL STARCH & FOOD Pvt.Ltd.

Sree Mangalmoorthi Starch Industries was started in the year

1990 for Native Starches and in 2010 Angel Starch & Food
Private Limited was established in Erode, Tamil Nadu.
Their core value of ‘Customer Focused Innovation’ has
made us emerge as one of the largest manufacturers, suppliers
and exporters of wide varieties of starch in India. We have a
registration and membership under the Certificate of
Agricultural and Processed Food Products Export
Development Authority. Under the guidance of Mr. V. P. S.
Radhakrishnan and his vast industry experience of 28 years,
we are able to deliver the best to our ever-growing clientele.

Their exceptional product range is well known in the

market. We are backed by state of the art infrastructure and
equipped with a processing unit, quality checking unit and a
warehouse and packaging section. Quality of the products has
always been our prime concern. We take stringent measures to
check our products on various parameters like composition,
viscosity, pH value, purity and effectiveness.

THEIR STARCH P RODUCTS FIND APPLICATION IN

VARIOUS SECTORS
Food

In order to give bread and cakes its fine texture, we

supply a wide range of starches which have excellent
thickening properties. The starches we offer also improve the
taste and freshness of the food. Texture is an important
constitutes in baking and we ensure that our starches give the
fine texture for all the bakery products.
 Fig 1.2.1 Maize / Corn Starch

Corn starch is a common food ingredient, used as Corn Flour

for thickening sauces or soups, and in making corn syrup and
other sugars It is versatile, easily modified, and finds many
uses in industry as adhesives, in paper manufacturing, as an
anti-sticking agent, and textile sizing application.

Table 1.2.1Company profile

Light Creatheir to white

DESCRIPTION color fine free flowing
powder
Insoluble in cold water&
SOLUBLITY in alcohol
pH ,10 % solution ,w/v 5 to 7
SOLUTION CLARITY, Clear to slightly hazy,
(20% SOLN w/v) without sediment.
Viscosity Of 3% Solution In 70 to 150 cPs
Brookfield Viscometer Model
:
LVDV II+ Pro Temp: 800c,
Spindle No.2 , RPM :100
MOISTURE CONTENT 13%
(w/w)
Ash content,% w/w on DB Max 0.50%
Starch ,% w/w on DB Min 98
Protein, % on DB Max 0.50%
Free Acidity, (ml of 0.1N MAX 40.00
NaoH/100)

Sulphur Dioxide, ppm Max 80.00

Food industry:

Thickener, Coating Agent, Binder.

Textile industry: Textile Sizing

Paper&Packaging: Used for fiber retention, internal sizing,

surface sizing and paper coating

Glue and Adhesive Industries

Binder in Packaging Industry

In bio-polymer industry: Briquette Binder, Binder in

explosive industry

Pharma industry: In conventional tablets and capsules, Starch

is used as a Diluent, Disintegrant, Binder, and Lubricant.
Nutraceutical industry: Used in a wide variety of applications
where film-forming properties are desired, such as for
Coatings, Barriers, Texture Modification & Binding.

Storage: Exhibits excellent stability when stored under cool

and dry ventilated place. Avoid direct sun light.

Fig 1.2.2 LAS 1 NF - Lactose Substitute Non Fat Solids.

Las 1 NF stabilises foam structure and prevents air

bubbles from collapsing. It is a common lactose substitute
used to replace SMP (Skimmed Milk Powder). It is used in
soft sweets and various confection coatings.

Lactose Substitute Non Fat Solids we export gives a light

dairy flavour and binds water to produce the firm, chewy
texture of confectionary cent.
 Fig1.2.3 Tapioca Starch

Tapioca starch we supply has multiple benefits and thus

it is used in the processing of many foods like soups, pastas,
noodles and salad dressings. The tapioca starch comes with
excellent thickening strength and it is also used as a binder
and stabilizer.

Fig1.2.4 Potato-Starch
 Potato starch is a very refined gluten free starch,
containing minimal protein or fat. This gives the powder a
clear white colour, and the cooked starch typical
characteristics of neutral taste, good clarity, high binding
strength, long texture and a minimal tendency to foaming or
yellowing of the solution. It is used in food & technical
application.

1.3 INDUSTRY PROFILE

INTRODUCTION ABOUT THE INDUSTRY

The Indian food industry is poised for huge growth,

increasing its contribution to world food trade every year. In
India, the food sector has emerged as a high-growth and high-
profit sector due to its immense potential for value addition,
particularly within the food processing industry.

Accounting for about 32 per cent of the country’s total

food market, The Government of India has been instrumental
in the growth and development of the food processing
industry. The government through the Ministry of Food
Processing Industries (MoFPI) is making all efforts to
encourage investments in the business. It has approved
proposals for 1joint ventures (JV), foreign collaborations,
industrial licenses, and 100 per cent export oriented units.

Market Size

The Indian food and grocery market is the world’s sixth

largest, with retail contributing 70 per cent of the sales. The
Indian food processing industry accounts for 32 per cent of
the country’s total food market, one of the largest industries in
India and is ranked fifth in terms of production, consumption,
export and expected growth. It contributes around 8.80 and
8.39 per cent of Gross Value Added (GVA) in Manufacturing
and Agriculture respectively, 13 per cent of India’s exports
and six per cent of total industrial investment. The Indian
gourmet food market is currently valued at US$ 1.3 billion
and is growing at a Compound Annual Growth Rate (CAGR)
of 20 per cent. India's organic food market is expected to
increase by three times by 2020#.

The online food ordering business in India is in its

nascent stage, but witnessing exponential growth. With online
food delivery players like Food Panda, Zomato, TinyOwl and
Swiggybuilding scale through partnerships, the organised
food business has a huge potential and a promising future.
The online food delivery industry grew at 150 per cent year-
on-year with an estimated Gross Merchandise Value (GMV)
of US$ 300 million in 2016.

Investments

According to the data provided by the Department of

Industrial Policies and Promotion (DIPP), the food processing
sector in India has received around US$ 7.54 billion worth of
Foreign Direct Investment (FDI) during the period April
2000-March 2017. The Confederation of Indian Industry (CII)
estimates that the food processing sectors have the potential to
attract as much as US$ 33 billion of investment over the next
10 years and also to generate employment of nine million
person-days.

Some of the major investments in this sector in the recent

past are

Global e-commerce giant, Amazon is planning to enter

the Indian food retailing sector by investing US$ 515 million
in the next five years, as per Mr. Harsimrat Kaur Badal,
Minister of Food Processing Industries, Government of India.

Parle Agro Pvt Ltd is launching Frooti Fizz, a succession

of the original Mango Frooti, which will be retailed across 1.2
million outlets in the country as it targets increasing its annual
revenue from Rs 2800 crore (US$ 0.42 billion) to Rs 5000
crore (US$ 0.75 billion) by 2018.

US-based food company Cargill Inc., aims to double its

branded consumer business in India by 2020, by doubling its
retail reach to about 800,000 outlets and increase market share
to become national leader in the sunflower oil category which
will help the company be among the top three leading brands
in India.

Mad over Donuts (MoD), outlined plans of expanding its

operations in India by opening nine new MOD stores by
March 2017.

Danone SA plans to focus on nutrition business in India,

its fastest growing market in South Asia, by launching 10 new
products in 2017, and aiming to double its revenue in India by
2020. Uber Technologies Inc plans to launch Uber EATS, its
food delivery service to India, with investments made across
multiple cities and regions.
Government Initiatives

Some of the major initiatives taken by the Government

of India to improve the food processing sector in India are as
follows: The Government of India aims to boost growth in the
food processing sector by leveraging reforms such as 100 per
cent Foreign direct investment (FDI) in marketing of food
products and various incentives at central and state
government level along with a strong focus on supply chain
infrastructure.

In Union Budget 2017-18, the Government of India has

set up a dairy processing infra fund worth Rs 8,000 crore
(US$ 1.2 billion).

The Government of India has relaxed foreign direct

investment (FDI) norms for the sector, allowing up to 100 per
cent FDI in food product e-commerce through automatic
route.

The Food Safety and Standards Authority of India

(FSSAI) plans to invest around Rs 482 crore (US$ 72.3
million) to strengthen the food testing infrastructure in India,
by upgrading 59 existing food testing laboratories and setting
up 62 new mobile testing labs across the country.
 The Indian Council for Fertilizer and Nutrient Research
(ICFNR) will adopt international best practices for research in
fertilizer sector, which will enable farmers to get good quality
fertilizers at affordable rates and thereby achieve food security
for the common man.

The Ministry of Food Processing Industries announced a

scheme for Human Resource Development (HRD) in the food
processing sector. The HRD scheme is being implemented
through State Governments under the National Mission on
Food Processing. The scheme has the following four
components:

Creation of infrastructure facilities for degree/diploma courses

in food processing sector

Entrepreneurship Development Programme (EDP)

Food Processing Training Centres (FPTC)

Training at recognised institutions at State/National level

Road Ahead
 Going forward, the adoption of food safety and quality
assurance mechanisms such as Total Quality Management
(TQM) including ISO 9000, ISO 22000, Hazard Analysis and
Critical Control Points (HACCP), Good Manufacturing
Practices (GMP) and Good Hygienic Practices (GHP) by the
food processing industry offers several benefits. It would
enable adherence to stringent quality and hygiene norms and
thereby protect consumer health, prepare the industry to face
global competition, enhance product acceptance by overseas
buyers and keep the industry technologically abreast of
international best practices.
 CHAPTER II

REVIEW OF LITERATURE

2.1. LITERATURE SURVEY

5S is a holistic application used to raise moral, ethical

standards and strongly associated with Japanese culture and
society. 5S not only improves organisational working
environment but also improves the overall industrial
management process performance as well (Ho, 1999b).

This practice is based on neatness, cleanliness,

standardisation and discipline in order to achieve quality
standards in goods and services (Ho and Cicmil, 1996; Patten,
2006; Liker and Hoseus, 2008; Samuels, 2009). Most of the
organisation workplaces face the problems of disorder,
wastage of time and cost due to non-value added activities.
These problems affect the work environment adversely, and
accumulate to bigger problems such as long lead times, higher
defects, low productivity, frequent breakdowns of machines
and hidden safety hazards, thereby critically affecting the cost
competitiveness of the organisations. These problems can
easily control and reduced by holistic 5S implementation at
workplace (Chapman, 2005; Chuanjie, 2013).

The implementation of 5S methodology not only play

significant role in the development of manufacturing sector,
but it also make remarkable evolution in defence, banking,
mining, agriculture, hospitals and construction sector
(Gratiela, 2012; Aziz et al., 2014; Flynn and Vlok, 2015).
 It is also analysed that the practice of 5S become the
supporting activity or in some cases as a base foundation for
the implementation of other lean tools such as TPM, TQM,
JIT, TPS and ISO standards (Teeravaraprug et al., 2011; Chen
and Tan, 2013; Kushwaha, 2015).

Abramovitch (1994) concluded that 5S is driven from

the bottom to up level in an organisation, when it is
implemented effectively with dedication of sincere efforts by
every employee from top management to bottom management
of staff. Ho (1997) has reviewed the reasons of having 5S
technique in Japanese industries. He concluded that 5S
practice was essential because it help to make the life of
everyone good in organisation. It was implemented
successfully with help of top management commitment,
promotional campaign, training of 5S, evaluation of the
results and keeping of records.

Ho (1999b) has researched the Japanese philosophy of

5S, and considered it as the base line for industrial
management. As the name were new for the western
countries. There meanings were translated in their language in
order to remove the complexity so that they can successfully
implement in the Western firms.
 ABK-AOTS Dosokai (2001) has reported that the Indian
industries have gained lot of benefits such as reduction of
customer complaints and worker absenteeism, improved
resources utilisation and worker morale through 5S initiatives
at workplace.

Becker (2001) has identified that most significant

barriers in the implementation 5S program are lack of
improved communication lines and lack of employee
involvement. He included that organisation were able to
implement 5S successfully with the removal of barriers but
the attitudes were gradually changed due to slow progress of
5S in some organisations. He suggested it is important to
continuously evaluate the progress of 5Sprogram by the
management to show the demonstration of their commitment
towards the program.

Brayer and Walsh (2002) have implemented 5S

Technique in the office of the mast international group
(Australia) in order to rediscover the value of TQM with the
practice of 5S. The results of the study revealed that there
were significant improvements realised by the organisation,
which helped in development of learning’s for the
encouragement of 5S practice in other international groups.
 Patra et al. (2005) have discussed the implementation of
office TPM initiative in conjunction with 5S methodology in
order to achieve performance enhancement benefits in the
Indian Institute of Production Management (IIPM) library at
Orissa in India. Office TPM is the critical element of TPM
implementation program which provides a systematic
approach for enhancing administrative and management of an
organisation by strengthening basic capabilities.

It provides a system capable of responding to any

change. Its aim is to reduce losses, provide better work culture
and environment with sense of ownership of the jobs which is
gained by the implementation of 5S through the awareness of
education, training and involvement of top management.

Maddox (2006) has concluded that commitment of

management and need of leadership for the program of 5S are
the most important requirement for its implementation in an
organisation. He demonstrated the importance of management
and various initiatives through their actions.

Maggie (2006) has explained that 5S technique has

widespread applications in the various sectors of
organisations. He shared his experiences of 5S
implementation in the library of university, where 5S practice
developed a strong relation due to the complete involvement
of all staff member with big hearted support. It developed
framework and dulcet environment for employees and
visitors.

Moreira et al. (2008) have implemented the 5S

technique to maintain the complex and dynamic system of
digital libraries. The authors developed 5SQual tool which
perform automatic evaluation to remove the problems before
they occur. It is applicable to various digital libraries and
sceneries due to its generic architecture. The evaluation
performed with 5SQual guided the design, development and
improvement of digital libraries and demonstrated the
evaluation of many aspects of the evaluated system.

Khamis et al. (2009) have investigated the 5S

implementation process and evolved 5S activity checklist for
manufacturing organisations. The authors concluded that 5S
can improve whole organisation in an integrated holistic
ways. They identified that most significant barriers of 5S
implementation are poor communication between top
management and shop floor employees and inadequacies of
training programs.
 Goetsch and Davis (2010) have studied that top
management have to play a crucial role in order to realise the
significance of 5S technique in the organisation among their
subordinates. The dedication and commitment from the
employees towards implementation of 5S program only build
on the promotion and proactive behavior of the top
management toward 5S technique.

Ho (2010) has investigated an integrated TQM model to

overcome the losses caused by oil crises and realising global
sustainability. The development of lean 5S checklist by the
author is aimed to minimised wastages of all sorts and reduces
down the financial problems. From vast experience, he
concluded that integrated Lean TQM model helped in global
oil energy consumption.

Gnanaguru et al. (2011) have demonstrated the

implementation in 6-S process improvement in an
aeronautical industry. The authors proclaimed that 6-S (5-S
and sixth ‘S’ as Safety) is considered as foundation of all the
improvement activities like TQM, TPM, Lean, etc.

Hunglin (2011) has implemented the principles of 5S in

Wang Chen manufacturing company in order to organise the
tools, improving the work environment and efficient
productive process. He introduced 5S methodology at Wang
Chen Company for addressing the problems like messy
environment, inefficiency, wastage of time and money. The
study revealed that 5S implementation led to reduction in time
wastage by 49% and provided more productive time to meet
the customer demands along with good profits.

Sorooshian et al. (2012) have presented experience of 5S

implementation and closely examined the effects of its
implementation. The study focused on planning and issues
from the manager’s and employee’s perspectives. The authors
have discussed the short and long term consequences of
implementing the 5S program. They found that 5S concept
strengthens and facilitates team work, discipline, productive
environment, ongoing commitment and maintain excellent
service with involvement from top to bottom level
management.

Suárez-Barraza and Ramis-Pujol (2012) have studied that

number of multinational companies are utilising 5S technique
as a vital step or main driver for the implementation of lean
thinking or lean-kaizen approach.
 Putro (2013) has reported that with the implementation
of 5S in Bengkel ABC, there was about 30,200 cm2 more
space available for the organising spare and waste in the
organisation.

The author concluded that 5S technique helped in the

effective utilisation of workspace and provides immediate
return within 48 days on its investment of implementing 5S
program. He added that 5S implementation was helpful in
providing better organising environment for spare and tools at
Bengkel ABC.

Pasale and Bagi (2013) have stated the practice of 5S

technique in small scale manufacturing industries has resulted
in enhancement of efficiency of production system from 67%
to 88% within a short span of few weeks.

Rojasra and Qureshi (2013) have reported that in Indian

economy, small scale industries play a significant role in
employment and industrial production with 33.33% of export
revenue. It is important to implement the basic lean tool (5S)
in small scale industries for their development. He concluded
that implementation of 5S in (SMES) bring vital improvement
of 88.8% in production system within sequential weeks.
 Singh et al. (2013) have experienced the implementation
of TPM in a machine shop. The success of TPM
implementation was measure by the overall equipment
effectiveness. The authors concluded that success of total
productive maintenance depend upon various pillar like 5S,
quality maintenance, kaizen and office TPM.

Kennedy et al. (2013) have discussed that popularity of

lean tools are not up to automotive manufacturing sector, they
effectively adopted in the processing industries also. Lean
tools such as 5S, single minute exchange dies (SMED), visual
management, etc., bring the overall improvement in
production and quality.

Jain et al. (2014) have studied that 5S tool has bring

significant improvement in the medium size organisation in
terms of quality, productivity and work culture. It strongly
aided to maintain organised environment with continuous
improvement and also contributed TPM implementation.

Khanna and Gupta (2014) have reported that Mayur

Uniquoters Pvt. Ltd. Company situated in Jaipur (India) have
improved the bad condition of the company with practice of
5S in the plant. The company image was totally changed with
huge benefits and thereby helped the company to receive the
Forbes Asia top 200 under billion awards in November 2012.

Ikuma and Nahmens (2014) showed that safety is an

inbuilt part of 5S in healthcare system. They concluded that
5S can facilitate process improvement, work environment and
safety.

Patel and Thakkar (2014) have reported the benefits of

5S in the various organisations. They have observed that 5S
technique drastically changes the image of the company.

Benefits such as cost reduction, efficiency, effectiveness,

quality, safety, security and pollution free environment were
obtained on the successfully implementation of 5S. The
authors also reported that it is very essential to provide
training of 5S technique to the employees.

Gupta and Jain (2015) have examined that

implementation of 5S at all the workstations of small scale
organisation considerably reduced the tool searching time
from 30 minutes to 5 minutes and make workplace efficiently
productive. They analysed that 5S is a powerful tool which
can be implemented in various industries whether it is micro,
small, medium or large.
 Sánchez et al. (2015) have studied that implementation
of 5S at SMEs in Bogota (Colombia) considerably improved
the selected four study factors namely with a rise of
productivity (44%), quality (44%), organisational climate
(52%) and reduction of risk (90%).
 CHAPTER III

DESIGN OF STUDY

3.1. OBJECTIVES OF THE STUDY

PRODUCTIVITY
5s increase the productivity of the organization.
Specially, it work in both personal and working life. The face
of an undisciplined office becomes discipline because of 5s.
SAFETY
When a man follows the 5s then increases the safety
issues of the organization.
REDUCE WASTE
5s tech to clean up the process by arranging the materials
in discipline way. Unwanted material are reduced from the
place by 5s methods.
WORKER COMMITMENT
Worker commitment becomes increase by appling 5s.

3.2. SCOPE OF THE STUDY

 The scope of present study is to have a better well
organised Angel starch and food pvt.ltd company by
implementing 5s.
 The House keeping index is been calculated.
 The 5s technique is implemented and the files and
records are maintained properly in a particular order.
 With the Analysis made various suggestions and
recommendations are given to the company.

3.3. LIMITATIONS OF THE STUDY

 It is been done based upon only one industry so it can’t
be implemented in the same way to all other industry.
 It is been done based on the present infrastructure of the
company which may change in future.
 It is been implemented based on the strength of workers
at the present time which can change in coming future.

CHAPTER IV

FINDINGS

5S AT ANGEL FOOD STARCH

4.1. LEAN MANUFACTURING

TOPICS
1. What is lean?
2. Why lean?
3. Principles of lean
4. Goals of lean
5. Types of waste
6. Lean tools
7. Steps to achieve lean system

What is lean?
 Lean is a systematic approach of eliminating waste so
every step adds value for the customer

What is value?
The right time at an appropriate price, as defined by the
customer.
 Cost
 Quality
 Delivery

What is waste?
  Waste is any activity that consumes time, resources, or
space but does not add any value to the product or
services.
5 Principles of lean
• Define value from the customer perspective
• Identify the value stream
• Make the process flow
• Pull from the customer
• Head towards perfection
5 Principles of lean
 Specify value
 Specify value from the standpoint of the end customer
by product family.
 Identify the value of stream
Identify all the step in the value stream for each
product family, eliminating whenever possible those
step that do not create value.
 Create flow
Make the value – creating step occur in tight
sequences so the product will flow smoothly towards the
customer.
  Let the customer pull product through the value
stream
Make only what the customer has ordered.
 Seek perfection
As value is specified , value stream are identified ,
wasted step are removed , and flow and pull are
introduced , being the process again and continue it until a
state of perfection is reached in which perfect value is
created with no waste .

FOUR GOALS OF LEAN

 Improve quality
 Eliminate waste
 Reduce time
 Reduce total cost
THE SEVEN FORMS OF WASTE

 Overproduction: Producing more than the internal or

external customer needs.

 Waiting: Long periods of inactivity for people,

information, machinery or materials.
  Transportation: Excessive movement of people,
information or materials.

 In appropriate processing: Using the wrong set of

tools, procedures or system.

 Unnecessary inventory: Excessive storage and delay of

information or products.

 Motion: People or equipment moving or walking more

than is required to perform the processing.

 Defect: Frequent error in paper work, product quality

problems etc.....

5S VISUAL WORK PLACE

 5s visual work place provide a clean environment .
 It is well organized and efficient.
 It provide the organization for preparing a rapid work
force .

JUST IN TIME
 It can lead to huge improvements in quality and
efficiency .
 This method was adopted by Japanese manufacturing
company.
  JIT means making what the market wants, when it
wants it.

WORK IN PROCESS
 It aims to minimize the work.
 It needs to store the inventory.
 It take time to look above and below work areas for
needed storage .

MATERIALS MANAGEMENT
 It is a branch of logistics and deals with tangible
components of supply chain.
 It can consolidate and efficiently handle core services.
 The parts and materials used in supply chain meets the
minimum requirements by performing quality assurance.

STEP TO ACHIEVE LEAN SYSTEM

The following step should be implemented in order to create
the ideal lean manufacturing system:
 Design a simple manufacturing system
 Recognize that there is always room for improvement
  Continuously improve the lean manufacturing system
design .

4.2. INTRODUCTION OF 5S

In recent years, organizations are well aware of modern

techniques and methods to implement quality management
and adopting advance systems like total quality management,
lean manufacturing, material flow cost accounting etc., to
enhance capability of individuals and processes.

5S is one of most widely opted techniques is commonly

used among the organizations from various segment in the
world in order to enhance productivity and human capability.
It is commonly studies that implementation of 5S
methodology could considerably raise the health, safety,
housekeeping as well as environmental performance in
manufacturing facility.

Because 5S methodology and its processes are dedicated

to cleanliness and standardization in workplace through
structured program to systematically achieve well organized
workplace, as result you can achieve safer, efficient and more
productive workplace.
What is 5s?
"5S is work culture practices for maintaining
workplace organized by a systematic and disciple method
that uses an acronym of five Japanese works which stand
for Seiri (Short), Seiton (set in order), Seiso (Shine),
Seiketsu (Standardization) and Shitsuke (Sustain)."

5S mean Good housekeeping techniques for enhancing

productivity, quality and safety at the workplace. Many
organizations are already practiced the 5S and achieved
significant benefits from effectively implemented all stages in
workplace. If you are implementing total quality management
or lean manufacturing, you have to initially and fundamental
step implement as 5S to track the continuous improvement as
operational level

Why good housekeeping?

 A neat and clean workplace has higher productivity.

 A neat and clean workplace meets delivery deadlines
better.
 A neat and clean workplace produces fewer defects.
 A neat and clean workplace reduces the cost by reducing
inventory.
  A neat and clean workplace increases morale of the
employees.
 A neat and clean workplace is a much safer place to
work.

But, 5S is more than housekeeping, it is system to reduce

waste and optimize productivity through sustaining a
systematic workstation and using visual indications to achieve
more stable operational results, because operational stability
required for making and sustaining continuous improvements
in workplace.

Fig4.2.1 5s methodology

ELEMENTS OF 5S
5S methodology represents five basic disciplines for
maintaining a visual workplace which is foundational to
continuous improvement and manufacturing strategic concept
to removing waste and well organized manufacturing facility.
The five stages - shorting, set in order, shine, standardize and
sustain that are also known as 5 elements of a visual
workplace. So, let's see all five elements of 5S:

1. Short- Short our items and discard the unnecessary.

2. Set in Order- A place for everything and everything is in
its place.
3. Shine- Clean your workplace thoroughly.
4. Standardize- Maintain Standard.
5. Sustain- 5S is a habit and is continually improved.

HOW TO EFFECTIVELY IMPLEMENTATION 5S?

 Very first you have to understand manufacturing and

supporting processes, production stages, process flow,
and material used in processes, identification of plants
resources to mapping 5S implementation at various
locations.
 Identify pilot locations and educate everyone working in
that area on 5S.
  Define 5S system's implementation related objective as
company object and include safety, and quality as on
initial implementation parts.
 Try to make the facility visual and make the workplace
easy to use.
 Brain storming for new methods to make work easy.
 Everyone is responsible for its location, machine and
workplace, define responsibility of key personnel.
 Maintain activities according to standards, in case of any
mistakes correct immediately.
 Identify root causes by 5 why method.
 Live 5S daily basis, sustain the 5S methodology

Fig 4.1.2 BEFOR 5S IMPLEMENTATION

5S ELEMENTS
1. SHORT
The first stage of the 5S system is short, states to the act of
segregate away all unwanted, unnecessary and unrelated
materials in the workplace. Simple meaning of this stage is to
short out between wanted and unwanted items at workplace
and removal of unwanted item. It is also initial cleaning stage
where all the not-needed items are elimination required for
better organize remain items.

WHY IS IT IMPORTANT?

 Time, money, energy, space and other resources can be

managed and used most effectively.
 Enhance communication between workmen.
 Frustrations and reduces problems in the work flow.
 Increases product quality and enhances productivity.

IMPLEMENTATION METHOD
o You have to decide what materials / items are necessary
and which materials / items are unnecessary or unwanted.
To identification of unnecessary items you should not
only verify the floor but also at your around your
workplace.
 o Very important is "Red Tag", put a red tag on all
unwanted items and keep them in a separate location.
o If any item(s) you used once or twist time in 6 to 12
months may located at a distance from your workplace.
o Any item(s) used frequently should be available and
accessible at a central point in the workplace.
o Any item(s) are not in used since one year, discard it.

The short refers to the practices of going through all the

tools, equipment, devices, materials, papers etc., in the
workplace and keeping only useful materials, that you remove
all items from the workplace that are not needed for current
operations and manufacturing transactions it does not mean
that you only eliminate that items that you know you may
never requirement, materials which is not currently in use it
should store offsite or discarded.

Red Tag
A red tag is strategic method of identifying and removing
all unnecessary items from the workplace through the use of
red tag as a visual control. Red tag is simple tag; the goal is to
remove nonessential materials from workplace. It is simply
putting red tag for all potentially unwanted materials and
moving it into a red tag area, red tagging helps in identifying
and disposing unwanted materials with due accountability and
authentication. See

Fig4.1.3 Red tag example

 The materials / items are red tagged and stored in a red
tag area for a specific time period, in case anyone can request
for any item if there is anything need otherwise it should be
disposes through recycling, trash or resale.

What red tag indicates?

 On which item having attached a red tag indicate this is

unneeded / does not belong in the workplace.
 On which item having attached a red tag indicate storage
area not specified for this item.
 Red tag indicates, reasons what each item is and why it
was tagged which is described in particular field of it.
 The item is moved for particular reasons, and what action
processes required on it.

Benefits of Short - 5S stage one

 Saving in use of Space.

 Removal of excess equipment/parts.
 More space made available in filing cabinets/shelf
 Avoidance of error.
 Easy access to things.
 Eliminate unsafe situations.
  Preventing rusting or damage to material
 Reduced inventory by sale of scrap material / excess.

Audit Checklist for short - 5S Stage: 01

 Do you find items scattered in your workplace, mean are
there items such as obsoleted or unused signage and
documentation on floors, callings, walls, table etc..,
within the area?
 Is there any unnecessary or excess equipment and device?
Is there obsolete or duplicated storage in the workplace?
 Are their equipment and tools placed on the floor?
 Are there boxes, papers and other items left in a
disorganized way?
 Are there items in the workplace area which require
achieving or have exceeded their lifetime?
 Is it recognizable which items are marked as unnecessary.
Has a Red Tag implementation or similar between
conducted or recently concluded?
 Are all items sorted out and placed in designated spots?
 Are tools and stationary properly sorted and stored?
 Is uncontrolled personal equipment / device or
belongings in the direct work area? Is there discarded
personal protective equipment within the workplace area?
  Review and use the item disposition list as the criteria for
red tagging, is there red tag included area, mark the
location, and identify a red tag specific location manager
write and post standards and rules for item disposition.

2. SET IN ORDER

Set in order or systematic arrangement is second stage of

5S system. Set in order / Seiton is A rational, orderly and
methodical arrangement of all items we use, re-work or write
off. Honestly, peoples say about set in order - "Place for
everything and everything in its place", I think is great quote
for this stage.

The goal of second stage of 5S system is every thinks in

the right places or set up so that they are readily available and
easily accessible for use, its eliminate searching of particular
thing needs for current operation. Here three basic
fundamentals of this stage are: (1) Organize items in such a
manner that they are easy to available, visible, accessible and
easy to use. (2) Sign / labelling them so that they are easy to
find and put back. (3) A place for all necessary items and
everything in its place, no more homeless items.
 The core team must come together to analyze the
workplace area for further improvement opportunities and
understand the situation to reduce sources of waste and
mistakes as well as to make the workplace more visually
instructive. The team must focus on some basic points such as
given as below:

 At the facility equipment, tools, utility, machinery,

electrical system etc.., must be well organized and
labeling to simplify tracing.
 Document layout, equipment and supplies.
 Every tools, and utility items must be kept near the point
of use, labeled and organized.
 To focusing on safety requirements, every workplace
must be provided hazard warning systems, safe working
instructions at the point of need. And ensure that, the
personal protective equipment is easy to access and ready
for use.
 To focus on manufacturing processes, every work
instruction must be updated, devices used in processes
must be mistake-proofing to prevent human and machine
errors.
  Every quality standard must be visually designed &
properly displayed as well display examples of which
kind of results will acceptable & unacceptable in if visual
display if possible.
 For easy accessibly and visual management for inventory,
and effective identification of production requirements
should be maintained accordingly. Every store room
inventory properly labeled and description, quantity as
well specific location must be maintained.

IMPLEMENTATION METHOD
 First of all, you have to decide the right place for
everything, or any item you have to put on the rack,
cabinet or at any place, reassign spaces if necessary.
 Deploy all materials, devices, tools, equipment etc., at a
place specified or allocated to them with proper label.
 Indicate / sign / label or numbers of maximum and
minimum to alert in case of over load stock situation.
 Use floor pain marking to define working area,
gangways, entry - exit ways, safety equipment, locations
etc.., this clearly identifies the location of equipment and
also warns people passing by not get too close.
  Maintain standards in color coding, specifically for
pipelines, water lines, gas lines etc. for equipment,
machinery specific color is also recommended.
 Overhead crane, water tanks, chemical / or any liquid
tanks etc., must be capacity defined and marked on
visible writing.
 Use display cautions, messages, instructions at proper
places at height and written clearly.

BENEFITS OF SET IN ORDER

 Helps reducing time consumed in searching materials for

use.
 Easy to inspect and recognize when material is taken out
from their location.
 Creates work effectiveness.
 Creates safety atmosphere.
 Helps in inventory control.
 Improve work place utilization.
 Better identification by using color coding, Such as
Yellow - Usable, Red - Unusable

AUDIT CHECKLIST FOR SET IN ORDER - 5S STAGE:

02
  Every workplace i.e. whole organization map / layout
must be preparing with identified work area that clearly
mentioned gangways, manufacturing areas, storage area,
recycling area etc.., because layout also helps to moving
large items or moving heavy quantitative items much
easier if each space is properly indicated. Verify the
same.
 Are there materials, tools, files or any other media
arranged in a manner that ensures repetition of storage
with no duplication?
 Are storage areas: Racks, Cabinet, and Floor etc., clearly
identified as specific allocation? Are walkways clearly
identified? Are there supplies (labels, tags, bins etc.)
identified?
 At facility, maintenance, store, operations etc., plant
marking standards determined?
 Is it clearly described which item is currently used in
processes? Are there processes to ensure that achieved
items are easily retrievable?

3. SHINE
Shine mean clean workplace. Includes the cleaning of
everything in the work area and keeping it clean. Bright place
where everyone will enjoy working. Keep everything in top
condition, so that when someone needs to use something, it is
ready to be used. But during the cleaning processes it must
take care, each member should be equipped with adequate
cleaning materials that have been tested to make sure the
solution will not harm any equipment, machine or work place.
It is expected that treat cleaning as an inspection process,
perform cleaning & inspection to understand work
environments on daily basis.

IMPLEMENTATION METHOD
 Determine the goal of shine, set up the targets and focus
on area where needs to implement.
 Make the division of total workplace area and allocate
responsibility for cleaning for each divided area.
 Decide on cleaning points, order of cleaning, type of
cleaning and cleaning aid required etc.
 Setup an effective schedule and assign individuals, as
well as display cleaning schedule at appropriate location.
 Prepare proper procedure for continued daily shine
processes.
  To focus on safety requirements: every team member
who performing this task must be equipped with safety
tools and personal protective equipment.
 Check specific equipment targets for necessary repairs
and replace anything if need.
 During the perform cleaning processes, make sure the
defective conditions such as loose wires, loose bolts and
nuts, vibrations, excessive sound, temperature etc., in
case found talk with maintenance superior for further
actions if you are not belonging to maintenance.
 Move the dust, materials removed during the cleaning
from various area store at specified / allocated dump
yard.
 Shine and inspect through cleaning every shift.

BENEFITS OF SHINE

 Good, neat & clean working place motivates for effective

functioning.
 Increases efficiency of machines / equipment.
 Extends machine and equipment life.
 Creates safe environment and working place.
 Helps ion identifying the potential cause of problems.
  Helps in developing the skill of operator for doing
autonomous maintenance
 Reduction of wastage.

AUDIT CHECKLIST FOR SHINE - 5S STAGE: 03

 Are there 5S (Shine) schedules & checking & auditing
schedules are defined? Responsibility & locations are
defined; make sure all workmen know their assignments?
Verify individual involvement in the process?
 Are the workplaces, equipment, machinery etc., kept
clean & shine and free from uncontrolled waste?
 Determine appropriate cleaning method, processes are
prepared? And peoples are follow it? People understand
it?
 Are the schedules & planning are performing initial
cleaning of targets using the initial cleaning plan?
 Are at information locations and notice boards kept up to
date?
 Are floor areas being clean, undamaged, without
slippery? Verify to consider safety requirements.

4. STANDARDIZE
 This aspect of the 5S focuses on standardization; it is the
outcomes that exist when the first three pillars - sort, set in
order and shine are properly maintained and constant routine.
This stage of 5S, forming a consistent way of implementing
the tasks that are performed on a day-to-day basis with all first
three stages of 5S. Standardization maintained through:

 Operation Standards / procedures

 5 minutes 5S
 Visual Control (Example: Warning lights, color coding,
labels, etc.)
 Schedules for cleaning / housekeeping
 Inspection / audit and checklists

You have to establish a work environment and structure

that will support the modern practices and turn them into
regular tasks / habits. The main purpose of 5S's fourth stage
"standardization" is to ensure that everyone in the organization
strictly follows the same standard operating procedure, the
same names of materials / products, the same name of
specifications, sizes, signalization, marking, shape and colour
etc.
 The goal of standardization is to establish best practices
and to get each member follow standards during
implementation and improve workplace practices accordingly.
To effectively implement standardization, you have to define
roles and responsibilities for each team member and it must be
clearly and consistently applied. The important task in the 5S
system is 5S communication board, where all the information
is needs to display for all peoples of organization, se example
picture:

Fig4.1.4 5S Communication Board

IMPLEMENTATION METHOD
 Prepare documented procedures / operations SOPs, work
instructions and guidelines for initial stages such as
shorting, set in order and shine for the visual workplace.
 To maintain standards, make the audit checklist for each
department, section and division as well as train your
people in using them.
 5S evaluation is one of the important tasks of 5S system,
carry out monthly, quarterly or periodic evaluation by
verify and using the audit checklists.
 Visual management is best part to implement and to act
faster for such as: Labels at each material, tanks,
equipment, chemical storage areas etc.
 Identify and categorize a condition to standardize.
 During the periodic 5s evaluation, needs to discover new
potential control ideas as floor condition. Choose, test
and implement control ideas at appropriate locations.
 Maintain & monitor those conditions and standards
defined.
 5S system related activities should be planned and
schedule at the frequency rate necessary to maintain a
clean, orderly and safe working environment.
BENEFITS OF STANDARDIZE

 Proper & Nice Working Areas

 Help in synchronizing the activities of SEIRI, SEITON &
SEISO
 Helps in educating the new persons joining the area on
standard methods in practice.
 Reduce breakdown and increase meantime between
failure
 Reduce the defects & breakdowns, and less scope for
errors and scrap.
 Visual management improves work efficiency (5'S' -
News, Poster, Badges, Slogans & celebrating 5 'S'
Day/Week.
 Work area looks more organized and safer.
 With better visual and transparency management work
efficiency will improve.

AUDIT CHECKLIST FOR STANDARDIZE - 5S STAGE:

04
 Is the workplace assumed control methods, are there
people easily understand and follows accordingly? Is
there you found any leakage in standard appearance in
 workplace? Are all information centers or 5S
communication board used as important points for
information?
 Is there working environment, climate setup is proper
such as temperature, lighting, ventilation, humidity etc.?
is workplace is well enough to be clear of heavy dust? Is
there lighting angles are properly set to comfort for
work?
 Is the first shorting, set in order and shine are being
maintained? Are we operating within the rules that setup
& agreed?
 All the people working in workplace are wear clothing
which is clean and undamaged? Is personal protective
equipment worm as prescribed?

5. SUSTAIN
To sustain means to make a habit of properly maintaining
correct procedures. Sustain also means discipline. It indicates
your assurance to sustain regularity and to practice first 4s as a
way of life. This also requires that your employees'
demonstration optimistic attentiveness & overcome resistance
to change.
 The stage focus that the 5S mentality is embedded in routine
in works and procedures. Some simple points that help to
understand & implement procedure for 5S - sustain:

 Establish the rules to keep the workplace well organized

& ordered as well track by established upon standards.

 Ensure that all the workmen, staff, operators and support

team must be trained for 5S procedures, work
instructions, safety instructions and operational
procedures.
 Establish proper structure of how and when 5S activities
will be implemented.
 Formulate guidelines for evaluation / audit of 5S
implementation.
 Educate and encourage participation through 5S concepts
and skills development, 5S communication Boards,
emails, visual displays, study groups and weekly 5S
activities.
 Draw up and audit system including checklist for 5S for
all the workplace, offices, shop floor, storage areas etc.
  Conduct periodic audit and monitor the scores through
radar charts / bar charts.
 Appreciate by awarding, appreciation to best workplace,
offices, zone etc.

5S audit processes must establish into practice to ensure

that all the stages of 5S are properly function and maintained
workplace organized as top priority as well as ensuring that
the routines & schedules are conducts as specified
standardization.

BENEFITS OF SUSTAIN

 Promotes habits for complying with work place rules and

procedures.
 Creates healthy atmosphere and good workplace.
 Improves Safety and Hygiene
 Improves morale of employees
 Develops team work
 Develops ability to think and analyze causes for
improving control system.
 Improvement of Company culture, rules, safety devices,
etc.
AUDIT CHECKLIST FOR SUSTAIN - 5S STAGE: 05
 Is there sustaining plan is prepared? And ensure that
management support for the plan?
 Whether everyone in the workplace area know about the
5S standards and their purpose? Are people within the
workplace trained in key procedures and practices as
well? Are there all the procedures are update regularly
and reviewed?
 Is there all equipment, tools, bill of materials,
information, files, etc., are stored correctly?
 Is there 5S communication board and other
communication devices are set and update regularly? Is
there information is easy for understand and readable?

Fig4.1.5 after 5s implementation

5S AUDIT

In the 5S methodology, audit is important part of the

whole system to ensure that processes established during all 5
activities, standardization continues to be maintained. To
sustain all 5S activities in organization need periodic
monitoring through audit scores, share information on 5S
communication board to declare results of improvements. 5S
audit is not just audit, its monitoring and improvement must be
involved in audit processes, it also verifies the involvement of
employees, and engage them in evaluating area outside their
workplace, providing support for other workplaces.

Fig4.1.6 After complete 5s implementation

CHAPTER V

SUGGESTIONS AND CONCLUSION

CONCLUSION

The study these company demonstrates the efficient

implementation of 5S technique leads to subsequent
improvement in productivity of the manufacturing company.
The 5S improves environmental performance and thus relate
primarily in reduction of wastes in manufacturing. It promotes
neatness in storage of raw material and finished products.

The 5S implementation leads to the improvement of the

organization in many ways for instance. The implementation
of the 5S system of rules leads to the following effects
regarding the improvement in quality:

 Visible results within a short period of time (2-3 weeks),

 Workers get used to order and discipline,
 Labelling draws attention to change that is about to
occur,
 Reduction of physical effort, less accidents during the
production process,
 Increase of the workers‟ professional training, better
organization of activities”.
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