case study concerning 5s method impact in an automotive company

Academia.edu no longer supports Internet Explorer.

To browse Academia.edu and the wider internet faster and more securely, please take a few seconds to  upgrade your browser .

Enter the email address you signed up with and we'll email you a reset link.

• We're Hiring!
• Help Center

Case study concerning 5S method impact in an automotive company

2018, Procedia Manufacturing

Related Papers

Sumeet Alhat

Under the concept of "Industry 4.0", production processes will be pushed to be increasingly interconnected, information based on a real time basis and, necessarily, much more efficient. In this context, capacity optimization goes beyond the traditional aim of capacity maximization, contributing also for organization's profitability and value. Indeed, lean management and continuous improvement approaches suggest capacity optimization instead of maximization. The study of capacity optimization and costing models is an important research topic that deserves contributions from both the practical and theoretical perspectives. This paper presents and discusses a mathematical model for capacity management based on different costing models (ABC and TDABC). A generic model has been developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization's value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity optimization might hide operational inefficiency.

Procedia Manufacturing

Martina Varisco

International Journal of Business and Systems Research

Tamás Koltai

Benny Tjahjono

Johan Stahre

Veikko Turunen

Nemanja Sremcev

Malin Tarrar (Karlsson)

RELATED PAPERS

Rahmawati Munir

Epidemiology (Cambridge, Mass.)

Jussi Kauhanen

idawati supu

Stanislav Korenko

Clara Gajardo Guzman

Organic Letters

ANGEL FABIAN ZAPATA VIDAL

F. Antoniou

Neuza Corte de Oliveira

Lebanese Medical Journal

Ahmad Mourad

Jaideep Srivastava

Historia de las …

Jose Fonfria Diaz

E-Mabis: Jurnal Ekonomi Manajemen dan Bisnis

Hristo Abrashev

Pamukkale University Journal of Engineering Sciences

Dilek şahin

Open-file report /

Kathryn Schoenecker

Medical principles and practice : international journal of the Kuwait University, Health Science Centre

Mustafa Aydin

Conservation Biology in Sub-Saharan Africa

Johnny Wilson

General and Comparative Endocrinology

Deborah Power

Lancet (London, England)

Fabio Tarantino

anthony downey

Authorea (Authorea)

Daniel Bracewell

European urology open science

Marco Puglisi

HAL (Le Centre pour la Communication Scientifique Directe)

Léonie Hénaut

RELATED TOPICS

•   We're Hiring!
•   Help Center
• Find new research papers in:
• Health Sciences
• Earth Sciences
• Cognitive Science
• Mathematics
• Computer Science
• Academia ©2024

Lean Safety - assessment of the impact of 5S and Visual Management on safety

J C Sá 1,2 , V Manuel 1 , F J G Silva 1 , G Santos 3 , L P Ferreira 1 , T Pereira 1 and M Carvalho 1

Published under licence by IOP Publishing Ltd IOP Conference Series: Materials Science and Engineering , Volume 1193 , 9th Manufacturing Engineering Society International Conference (MESIC 2021) 23rd-25th June 2021, Gijόn, Spain Citation J C Sá et al 2021 IOP Conf. Ser.: Mater. Sci. Eng. 1193 012049 DOI 10.1088/1757-899X/1193/1/012049

Article metrics

946 Total downloads

Share this article

Author e-mails.

[email protected]

Author affiliations

1 School of Engineering, Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, 431, 4200-072 Porto, Portugal

2 Instituto Politécnico de Viana do Castelo, Rua Escola Industrial e Comercial Nun Alvares - 4900-347 Viana do Castelo - Portugal

3 School of Design, Polytechnique Institute of Cávado and Ave, Campus do IPCA - Lugar do Aldão, 4750-810 Barcelos, Portugal

Buy this article in print

This study was developed in a furniture company and aimed to implement some Lean tools, such as 5S and Visual Management to reduce waste, by improving the production process. To carry out this analysis an observation plan was used, having the Spaghetti diagram as a reference as well as the value-added analysis of the operations. The implementation of 5S's allowed the improvement of the visual management and the organization through a reorganization of the layout, as well as normalization of the production process. With this, a reduction of 40% was achieved in terms of waste related to activities that did not add value to the product, such as unnecessary movements, waiting times and even movement of materials, having achieved a level of productivity of 74% and 87% in the finishing and joinery sections, respectively. In addition to improvements in the production process, the impact of the measures at the safety level (lean safety) was assessed. For this purpose, a questionnaire was prepared to assess the opinion of the employees, in which 40% considered that the implementation of the tools provided a greater motivation to develop their work activities safely.

Export citation and abstract BibTeX RIS

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence . Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

Case study concerning 5S method impact in an automotive company

• Scinapse’s Top 10 Citation Journals & Affiliations graph reveals the quality and authenticity of citations received by a paper.
• Discover whether citations have been inflated due to self-citations, or if citations include institutional bias.

Evaluating the Impact of 5S Implementation on Occupational Safety in an Automotive Industrial Unit

• Conference paper
• First Online: 17 April 2019
• Cite this conference paper

• Joana P. R. Fernandes 4 ,
• Radu Godina 5 &
• João C. O. Matias 4 , 6  

Part of the book series: Springer Proceedings in Mathematics & Statistics ((PROMS,volume 281))

Included in the following conference series:

• International Joint conference on Industrial Engineering and Operations Management

880 Accesses

2 Citations

Lean is becoming a world-class word that represents continuous improvement and most of all the importance of focusing on creating value. The implementation of Lean Manufacturing will lead us to improve quality, reducing costs and at the same time the elimination of non-value-added activities. For these reasons, several organizations try to adopt the philosophy. Although the application of Lean principles brings numerous benefits to organizations, at this time the optimization of the productive process is not enough. Ensuring optimal safety conditions of all the employees has been one of the top priority, exceeding “quality” or “performance” as indicators of success. In this paper, a case of study in one industrial unit of one of Europe’s largest car producers is tested and then it is evaluated how the implementation of lean tools, more specifically 5S , can contribute to the occupational safety conditions. The present work demonstrates another of the several advantages that is obtained from the use of 5S . Apart from being a powerful tool for organizing and optimizing the workplace environment, this study demonstrates that it is also essential to ensure occupational safety.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

• Available as PDF
• Read on any device
• Instant download
• Own it forever
• Available as EPUB and PDF
• Durable hardcover edition
• Dispatched in 3 to 5 business days
• Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Ciccullo, F., Pero, M., Caridi, M., Gosling, J., Purvis, L.: Integrating the environmental and social sustainability pillars into the lean and agile supply chain management paradigms: a literature review and future research directions. J. Clean. Prod. 172 , 2336–2350 (2018)

Article   Google Scholar  

Marodin, G., Frank, A.G., Tortorella, G.L., Netland, T.: Lean product development and lean manufacturing: testing moderation effects. Int. J. Prod. Econ. 203 , 301–310 (2018)

Alefari, M., Salonitis, K., Xu, Y.: The role of leadership in implementing lean manufacturing. Procedia CIRP 63 , 756–761 (2017)

Soliman, M., Saurin, T.A.: Lean production in complex socio-technical systems: a systematic literature review. J. Manuf. Syst. 45 , 135–148 (2017)

Shah, R., Ward, P.T.: Lean manufacturing: context, practice bundles, and performance. J. Oper. Manag. 21 , 129–149 (2003)

Sundar, R., Balaji, A.N., Satheesh Kumar, R.M.: A review on lean manufacturing implementation techniques. In: Procedia Engineering, pp. 1875–1885. Elsevier (2014)

Google Scholar  

Arunagiri, P., Gnanavelbabu, A.: Identification of high impact lean production tools in automobile industries using weighted average method. In: Procedia Engineering, pp. 2072–2080. Elsevier (2014)

Korkut, D.S., Cakıcıer, N., Erdinler, E.S., Ulay, G., Muhlis, A.: 5S activities and its application at a sample company. J. Biotechnol. 8 , 1720–1728 (2009)

AL-Tahat, M.D., Jalham, I.S.: A structural equation model and a statistical investigation of lean-based quality and productivity improvement. J. Intell. Manuf. 26 , 571–583 (2015)

Pinto, J.L.Q., Matias, J.C.O., Pimentel, C., Azevedo, S.G., Govindan, K.: Just in Time Factory: Implementation Through Lean Manufacturing Tools. Springer (2018)

Veres (Harea), C., Marian, L., Moica, S., Al-Akel, K.: Case study concerning 5S method impact in an automotive company. Procedia Manuf. 22 , 900–905 (2018)

Jilcha, K., Kitaw, D.: Lean influence on occupational safety and health in manufacturing industries. Glob. J. Res. Eng. (2016)

Sari, A., Suryoputro, M., Rahmillah, F.: A study of 6S workplace improvement in ergonomic laboratory. In: IOP Conference Series: Materials Science and Engineering (2017)

Pacana, A., Woźny, A.: Draft questions of 5S pre-audit with regard to health and safety standards for tires retreating plant. Prod. Eng. Arch. 13 (4) (2016)

Gul, M., Ak, M.F.: A comparative outline for quantifying risk ratings in occupational health and safety risk assessment. J. Clean. Prod. 196 , 653–664 (2018)

ISO 45001, Occupational health and safety. https://www.iso.org/iso-45001-occupational-health-and-safety.html

ISO 45001: 2018(en), Occupational health and safety management systems—Requirements with guidance for use. https://www.iso.org/obp/ui/#iso:std:iso:45001:ed-1:v1:en

Anaya-Aguilar, R., Suárez-Cebador, M., Rubio-Romero, J.C., Galindo-Reyes, F.: Delphi assessment of occupational hazards in the wineries of Andalusia, in southern Spain. J. Clean. Prod. 196 , 297–303 (2018)

Lay, A.M., Saunders, R., Lifshen, M., Breslin, F.C., LaMontagne, A.D., Tompa, E., Smith, P.M.: The relationship between occupational health and safety vulnerability and workplace injury. Saf. Sci. 94 , 85–93 (2017)

Camuffo, A., Stefano, F.D., Paolino, C.: Safety reloaded: lean operations and high involvement work practices for sustainable workplaces. J. Bus. Ethics 143 , 245–259 (2017)

Kelby, J.: How to use lean to improve and drive safety performance. Presented at the ASSE Professional Development Conference and Exposition, 9 Sept 2014

Li, S., Wu, X., Zhou, Y., Liu, X.: A study on the evaluation of implementation level of lean construction in two Chinese firms. Renew. Sustain. Energy Rev. 71 , 846–851 (2017)

Horberry, T., Larsson, T.J., Johnston, I., Lambert, J.: Forklift safety, traffic engineering and intelligent transport systems: a case study. Appl. Ergon. 35 , 575–581 (2004)

Download references

Acknowledgements

This work was financially supported by the research unit on Governance, Competitiveness and Public Policy (project POCI-01-0145-FEDER-006939), funded by FEDER funds through COMPETE2020—POCI and by national funds through FCT—Fundação para a Ciência e a Tecnologia. Radu Godina would like to acknowledge financial support from Fundação para a Ciência e Tecnologia (UID/EMS/00667/2019).

Author information

Authors and affiliations.

DEGEIT, University of Aveiro, 3810-193, Aveiro, Portugal

Joana P. R. Fernandes & João C. O. Matias

Research and Development Unit in Mechanical and Industrial Engineering (UNIDEMI), Department of Mechanical and Industrial Engineering, Faculty of Science and Technology (FCT), Universidade NOVA de Lisboa, 2829-516, Caparica, Portugal

Radu Godina

GOVCOPP, University of Aveiro, 3810-193, Aveiro, Portugal

João C. O. Matias

You can also search for this author in PubMed   Google Scholar

Corresponding author

Correspondence to João C. O. Matias .

Editor information

Editors and affiliations.

Department of Military Science and Technology, Portuguese Military Academy, Amadora, Portugal

Department of Exact Sciences and Engineering, Portuguese Military Academy, Amadora, Portugal

Sandra Pinelas

School of Technology and Management, Polytechnic Institute of Viseu, Viseu, Portugal

Rights and permissions

Reprints and permissions

Copyright information

© 2019 Springer Nature Switzerland AG

About this paper

Cite this paper.

Fernandes, J.P.R., Godina, R., Matias, J.C.O. (2019). Evaluating the Impact of 5S Implementation on Occupational Safety in an Automotive Industrial Unit. In: Reis, J., Pinelas, S., Melão, N. (eds) Industrial Engineering and Operations Management II. IJCIEOM 2018. Springer Proceedings in Mathematics & Statistics, vol 281. Springer, Cham. https://doi.org/10.1007/978-3-030-14973-4_13

Download citation

DOI : https://doi.org/10.1007/978-3-030-14973-4_13

Published : 17 April 2019

Publisher Name : Springer, Cham

Print ISBN : 978-3-030-14972-7

Online ISBN : 978-3-030-14973-4

eBook Packages : Mathematics and Statistics Mathematics and Statistics (R0)

Share this paper

Anyone you share the following link with will be able to read this content:

Sorry, a shareable link is not currently available for this article.

Provided by the Springer Nature SharedIt content-sharing initiative

• Publish with us

Policies and ethics

• Find a journal
• Track your research