BHARAT PETROLEUM CORPORATION LIMITED

KOCHI REFINERY

STUDY REPORT ON 5S IMPLEMENTATION

The undersigned along with Mr. Pugazhendhi V (Chief Manager,
Maintenance), Bharathan E M ( Assistant Manager, Maintenance), Harsh L
K ( Assistant Manager, Maintenance) had attended a one day training on 5S
Implementation conducted by TVS Training and Services Ltd at Madras
Management Association on 29/04/2016, and the report is as below:
5S Implementation
5S Stands for
Seiri : Sorting
Seiton : Systematic Arrangement
Seiso : Spic and Span
Seiketsu : Standardisation
Shitsuke : Self Discipline
Out of these 5S, Seiri is currently in progress which is sorting out the wanted
from the unwanted and removal of the latter. Once Seiri is completed, then a
sytematic arrangement of Wanted Items is to be done for which the following
points may be considered:

1. Introduction of Tool Box Storage Cabinets

Figure shows how Tool Boxes and Helmets are kept at Maintenance Shop
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As of now, Tool Boxes and Helmets are placed in a very disorderly manner at
the Entrance of the Maintenance Shop itself. This stands against the very
principle of 5S which is A Place for everything and everything in its
place. This situation can be changed by providing an appropriate stacking
technique for the Tool Box and Helmet belonging to every technician. This is
shown below:

Figure shows a sample Cabinet

Figure shows a Draw out Tray for Keeping the Tool Box. It can be designed for
various loadings to support the Heavy weight of the Tool Box.
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The advantages of this stacking technique is that:

Tool Boxes can be easily accessed and kept safe

Helmets, Boiler Suit etc can be kept in a single place
Each Locker can be locked by the Technician and he can be sure of its
safety.
More space available for keeping items as well as good appearance on
the outside

As a second phase, the Tool Box itself needs to be have an

improvement in terms of 5S. The Figure below shows how Tool Boxes
are maintained at some places.

Figure shows the present scenario of Tool Box condition

Disadvantages of Present Scenario:

Difficult to find a specific tool
Missing tools cannot be identified
Tool damage when kept randomly
Hand injury while searching for tools
Tools will get damaged

To combat this, Shadow Foam Design may be introduced in every Tool Box.
This is simply creating a Foam like filling inside the Tool Box which is to be
designed to hold every tool.
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Figure shows Foam being cut out for storing Tools in the existing Tool Box

With this shadow foam technique being implemented, every tool will be kept
in an orderly manner and most importantly, every Tool will be kept in its best
quality.

For any new Maintenance Units coming up, the concept of Tool Box must
be replaced by Shadow Tool Box Cabinets for each Technician.

Figure of Shadow Tool Box Cabinets

Advantages:

Missing items can be easily identified

Items can be easily retreived without any delay ; Cuts down on wasted
motion
Tools are maintained in good condition
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Portable Trolley Type can be easily moved to location of Work if required

Larger storage space
Professional way of Stacking tools

2. Colour Tagging

Figure showing the Colour Codes used for various purposes.

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Figure shows how colour coding is to be implemented

Figure shows a Work Floor with Colour Coding implemented

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a. Red Tag Areas

Seiton focuses on Systematic Arrangement and Red Tag implementation does
just the same.

Figure shows how unwanted equipments are kept at Maintenance Shop

The Red tag is a tool used to identify unnecessary items that need to be either
thrown out or relocated. They are especially useful as a visual management
tool as they easily communicate visually to other staff members that the
tagged items are unneeded/unwanted.

Figure shows a sample Red Card

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Figure shows how Red Tags may be placed in the Maintenance Shop

Figure shows Red Tagged Objects placed in a Red Tag Location

Taking these facts into consideration, the following changes may

implemented:
Identifying locations as Red Tag Areas for keeping items that are
pending for scrap/disposal. This includes the Drums that are kept in
Maintenance Shop for discarding Metallic/Non-Metallic Waste. They
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may be placed in Red Tag Areas near that Equipment enabling proper
placement and easy disposal.
Items placed in Red Tag areas must be documented and the list must
be reviewed every 15 days to sort out the Red Tag objects regularly.

b. Green Tag Areas

Green Tag Areas can be used for materials that may be used in future but
cannot be returned back to Warehouse. These include Gearboxes, Couplings,
Fan Blades, etc and other small equipments that may not be used in the near
future but will be used some time. These need to be tagged with a Green Tag
which stands for Raw Materials and need to be documented and reviewed just
like that for Red Tags.

Figure shows spares kept unused for a long time

Advantages of Green Tagging:

Equipments lying in the Maintenance Shop unused for a long time can
be easily identified at any point of time.
Usable condition at any point of emergency.
Place for everything and everything in its place

c. Red/White Areas
Red/White Colour Coding is used to identify locations of Fire Fighting
Equipment, First Aid Boxes and other items to be used in times of an
emergency. It can save a lot of time in searching when any such accident
happens.
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Figure shows the importance of Red/White Colour Coding

3. Document Storage
Coloured Files for easy identification of Different types of Files
Poka Yoke Technique, in other words Mistake Proofing can help
identify any missing file immediately at sight. It can be done in a simple
way just by drawing a line at an angle on the files placed in order as
shown below.
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Figure shows how Poka Yoke helps identify missing files

Conclusion
Awareness regarding 5S Activities is to be created through Before-After Cards
which clearly show how Good Housekeeping practices can change the look of
the Workplace. Since 5S is a group effort, everybodys participation is
essential for a wonderful result.

Sachin V Mathew
Management Trainee
Reliability Centre

SM (Maintenance-A4) DGM (Maint)