REVIEW ON IMPLEMENTATION SYSTEM IN EDUCATIONAL LABORATORIES L.Ramanathan1, S.Jeevanantham2, D.Logu3, V.Purushothaman4 1Assistant Professor, 2,3,4UG Scholar, Department of Mechanical Engineering, Sri Ramakrishna Engineering College, Coimbatore, Tamil Nadu, India

ABSTRACT educational laboratory. Using 5S, the The purpose of this review paper is to laboratory was expected to improve in the study the significance of imple menting areas of working environment, safety, s ome of principles of the 5s and kaizen to reduction of equipment search time, and enhance the productivity of increase deficiency. manufacturing organizations to become Educational laboratories that provide more efficient and more productive. 5s is students with experiential learning that a basic tool of systems create knowledge through insights gained by which is used for sorting, organizing and practical experience has become an integral systemizing the necessary things for job part of undergraduate STEM education place enhance ment. The research findings (Reck, 2016). Universities and technical from the literature review shows that the colleges aim to close the gap between theory industries have developed the necessity of and industrial practice using educational imple menting the 5s in the job shop and laboratories. These laboratories have according to them, implementing the 5s is technical resources and comparable relatively possible. Moreover, the functional characteristics with industrial educational institute’s labs has been a facilities (Jimenez et. al., 2015). They platform whe re 5s can also be prepare students with the skills required to imple mented. It is also to make the work in a professional environment (Gibbins student teachers become aware of & Perkin, 2013). With shared similarities, different plans and organizing skills; the gap between educational laboratories and develop an insight into the responsibilities industrial facilities can be narrowed through and help them in becoming a leader to the adoption of professional continuous manage physical, human and financial improvement techniques such as the 5S for resources. workplacestandardization.This study was conducted in the surveying laboratory in the 1. Introduction Engineering and Biological Sciences 5S is one of the first techniques used by building at Western Kentucky University organizations that adopt methodologies such (WKU), which is equipped to provide as lean, total quality management, and six- students with hands-on experiential sigma. Organizations learn that it is difficult knowledge during field data collection.The to have well-defined operational procedures, surveying laboratory seeks to provide improved working conditions, and quality students with the required experience. The products without 5S (Jugraj & Inderpreet, laboratory practicums are conducted with 2017). The 5S technique consists of five this goal in mind.The researcher visually steps. In Japanese the words are Seiri(sort), observed the surveying laboratory in WKU Seiton (set-in-order), Seisou (shine), Seiketsu and established the need to implement 5S. (standardize), and Shitsuke (sustain). 5S is a The study population were surveyed pre and lo w-cost technique used by organizations to post implementation to assess the perceived clean, order, organize, and standardize the impact of 5S based on selected performance workplace. This study implemented 5S in an metrics. The study was divided into three

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INTERNATIONAL JOURNAL OF CURRENT ENGINEERING AND SCIENTIFIC RESEARCH (IJCESR) parts. The first was to provide an approach cleaner environment for students, clearly for implementing 5S in an educational labelled equipment areas to reduce laboratory. The second was to implement 5S equipment search time, and increased in a surveying laboratory. The third was to workspace for easier movement after unused assess the benefit of 5S and present the items have been disposed. The purpose of results with future recommendations. the study was to assess the significant changes in performance metrics pre and post 1.1 Pro ble m State me nt implementation of 5S in the laboratory. From visual observation and conversation 2. Hypothesis with faculty, the surveying laboratory The study hypothesis follows: requires organization as it has become 1. After implementing 5S, efficiency will unsafe for its users due to the clutter of increase. equipment, unwanted boxes, long equipment 2. After implementing 5S, workspace will search time, and congested workspace. increase. Although the laboratory has some 3. After implementing 5S, equipment search instructions, it is lacking in organization time will be reduced. with little existing standardization in place or 4. After implementing 5S, laboratory well-defined work procedures. It is critical working environment will be improved. that educational laboratories become 5. After implementing 5S, safety will be standardized to improve lab ergonomics and improved. prepare students for industrial careers. An 2.1 Assumptions unstandardized laboratory results in higher The study assumed the following: equipment search time, smaller workspace 1. Participants were willing to take part in the due to unwanted materials and equipment, distinct phases of the researchthat ensure the reduced efficiency (i.e. longer time to carry success of 5Simplementation. out experiments), and poor working 2. The participants were honest in their answers environment. to the survey based on the selected performance measures. 1.2 Significance of the Research 3. The time-frame selected for the The significance of the research was to implementation of 5S wassufficient. implement the 5S technique in standardizing and improving the ergonomics of the 2.2 Limitations and Delimitations surveying laboratory by providing a The implementation of 5S requires participants framework for other professionals to having a basic understanding of the concept of successfully pursue its replication in similar 5S phases. The study is limited by the lack of educational laboratories or other industries. previous knowledge about 5S by the In addition, it also assessed the benefits of participants, which might have affected the implementing the steps of 5S in an responses. In this study, 5S implementation was educational laboratory. The benefits of delimited to the surveying laboratory in implementing the 5S technique in Western Kentucky University. In addition, manufacturing and other industries have although 5S is a continuous improvement been extensively discussed in other studies. technique, its implementation was delimited to This study emphasized the benefits of six weeks and one laboratory. applying this technique to improve safety 2.3 Definitions of Terms and equipment search time, laboratory Terms used during the study: working environment, increase workspace, 1. Continuous Improvement (CI) Methodology: and efficiency in a surveyinglaboratory. These are methods that continuously improve 1.3 Purpose of the Research processes and standards. The purpose of the research was to 2. Lean: A methodology for eliminating seven standardize and improve the ergonomics of types of wastes (muda) in a process. the surveying laboratory in WKU by 3. Standardization: Standardization is the implementing the 5S technique. The documentation of best practices ineach expected results at the end of the research process/project. If best practices are well was shorter time for experiments, safer and documented there is room for continuous

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INTERNATIONAL JOURNAL OF CURRENT ENGINEERING AND SCIENTIFIC RESEARCH (IJCESR) improvements. Singh and Ahuja (2014), “despite the simplicity 4. JIT: According to Gunasekaran and Lyu, of 5S, organizations have had difficulties in its Just-in-Time is the method of producing what is implementation” (p. 274). These difficulties are needed, at the time needed, and in the amount closely linked to existing gaps between theory needed (as cited in Singh & Ahuja, 2012, p.67). and practice of 5S that is evident in many 5. Kaizen (Continuous Improvement): Kaizen is research papers (Kobayashi, 2009). The review a Japanese word whichmeans “incremental of literature identifies the gaps by highlighting improvements” – quick and easy. the misconceptions regarding 5S 6. PDCA (Plan, Do, Check, Act): The PDCA is implementations. This critical examination a continuous improvement cycle, also referred aided in the strategy deployed for the to as Deming cycle or Shewhart cycle. implementation of 5S in this research. Third, According to Sokovic et al. (2010), PDCA the literature review highlights the benefits of cycle is an effective method of continuously 5S from studies undertaken by other seeking improvements and adopting “the right researchers, which provides a benchmark for first time”approach. the study’s performance measurement. 7. TQM (Total Quality Management): Total The chapter is organized as follows. The first Quality Management is a continuous section gives a brief history and discusses improvement strategy by management to instill dive rse concepts of 5S. The second section a culture in the organization for delivering high- discusses the components of 5S. The third end quality products. section discusses imple mentation strategies 8. TPM (Total Productive Maintenance): Total and that we re adopted for the study. The Productive Maintenance is a proactive strategy fourth section discusses the relationship of scheduled maintenance of manufacturing between 5S and continuous improvement equipment to prevent machine break-down or methodologies. The fifth section emphasis the faults that will impact the quality of the product. applicability of 5S deployme nt in TPS (): Toyota laboratories case studies. This section Production System is a production system considers an educational laboratory to be a developed by Toyota for the elimination of service related organization. As such, only wasteful practices such as muda (waste), muri service related case studies werediscussed. (overburden), and The sixth section discusses the evaluation 9. Quality Cycle: A sequence of activities aimed methods used to assess the benefit of at improving processes. 5Simplementationand the seventh section 10. ISO: International Organization for lists some of the benefits of 5S Standardization that establishes universal imple mentation. The eighth andninth standards for production of products. sections discuss imple mentation barrie rs and 11. IMS (Integrated Management System): misconceptions in the adoption of 5S in Integrated Management System is the organizations. The review of publis hed combination of individual management systems litera ture led to a broa der a pproach fo r the to develop an effectiveintegrated research described in this thesis. The manufacturingsystem. approach was outlined and justified. 2.4 Review of Literature 3. The 5S Components The review of literature serves the following The acronym of 5S have been translated into purposes. First, provide an overview of 5S English equivalents by Hirano (1995) as sort, based on scholarly articles to provide a context set in order, shine, standardize, and sustain. for 5S implementation within organizations. It This is the most frequentlyused and easy to introduces the implementation strategy adopted understand equivalents. Other variations include in published works to create a framework for the ONCSD, 5C, and CANDO (Kobyashi, the implementation of 5S within an educational 2009). Table 1 shows the different variations. laboratory. Throughout this research, the English Second, it identifies the existing gap in 5S equivalents of 5S by Hirano was used. implementation in other literature. According to

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INTERNATIONAL JOURNAL OF CURRENT ENGINEERING AND SCIENTIFIC RESEARCH (IJCESR)

Figure 1. The relationship between 5S (ONCSD) components (Osada,1991).

3.1 5S Implementation Strategy Organizations have adopted different 3.2 The Applicability of 5S in Laboratories strategies in the implementation of 5S. The According to Jiménez et al. (2015), 5S has most common strategy is implementing each been applied to various kinds of laboratories phase of the 5S sequentially. However, in various parts of the world. Case studies on Hirano (1995), in his book 5 Pillars of the the application of 5S in these kinds of Visual Workplace, suggested the following laboratories (chemical, educational, strategy for 5S implementation: (1) pharmaceutical) will be discussed below. Establish 5S promotion in the organization, This section, reviews case studies of the (2) Establish 5S promotion plan, (3) implementation of 5S in laboratories as a Establish 5S campaign materials, (4) In- mea ns o f attaining industrial standard. In the house education, (5) 5S implementation, and study, Implementing the 5S Methodology for (6) 5S evaluation and follow up. According the Graphic Communications Management to Malik (2014), Hirano’s strategy required Laboratory at the University of Wisconsin- that the simplest methodologies be executed Stout (2011), 5S was implemented in the first. The strategies adopted in more recent laboratory to provide a more efficient work times in the West is largely linked station layout with organized and labeled toHirano’s six-step strategy storage of items and equipment. The (Kobayashi,2009). outcome of the study showed that 5S was Another strategy widely adopted in the applicable to a film laboratory. After the West is the Deming’s plan, do, check, and implementation of 5S,the GeM lab 130, act (PDCA) cycle. Sidhu et al. (2013), study became well-organized, safer, more efficient, is a notable example of applying the PDCA and cleaner. The impact o f 5S cycle. During the plan cycle, data was implementation during the study was collected after investigations. In this cycle, determined by photographs. training is conducted, and each member of A study by Chitre (2010), Implementing the the team is assigned duties, which are 5S Methodology for Lab Management in the displayed on a notice board. In the do cycle, Quality Assurance Lab of a Flexible 5S phases are implemented in Packaging Converter was conducted to theorganization. At the third cycle check, organize, clean and manage the laboratory as evaluations are conducted to determine if 5S a means of improving efficiency. The results is successful and to discover possible areas from this study were measured through of improvement. The last phase act, the 5S before and after pictures that showed is continuously revisited in the organization improvements in organization of tools, and workers are recognized based on their cleaner environment, visual workplace, and commitment to 5S. storage space utilization. According to Chitre

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INTERNATIONAL JOURNAL OF CURRENT ENGINEERING AND SCIENTIFIC RESEARCH (IJCESR) (2010), for the benefits of 5S implementation discusses the methods of evaluating the to be sustained it must be adopted as a part performance of 5S and the method adopted of lean. In addition, 5S was viewed as a for this research. housekeeping technique and as such there 3.3 Benefits of 5S Imple mentation was low management and The major benefits of implementing 5S employeeinvolvement. include increased productivity, promptness, Implementation of 5S in a chemical enhanced confidence, less accidents, less laboratory at a medical device company was equipment breakdowns or downtimes, done by Tran (2011). The study was increased workspace, improved conducted to implement lean six sigma performance, and reduction in principles for which 5S was a part. The need documentation (Baral, 2012), In the study to re-organize the laboratory to improve Implementation of 5s Management Method workflow was determined. In addition, the for Lean Healthcare at a Health Center in laboratory required organization because of Senegal: a Qualitative Study of Staff the clutter of unwanted supplies. After the Perception, implementation of 5S brought implementation of 5S, efficiency and about improvements in the work responsiveness were improved, which led to environment, attitude and behavior of cost reduction. Furthermore, the distance patients and employees, quality of services between the workstation and materials were efficiency,patient-centeredness,and safety reduced. This caused a reduction in the (Kanamori et al., 2017). These benefits were distance traveled for preparing a solution determined by interviews with 21 from 468 feet to 245 feet. The cycle time participants regarding their perceived was also reduced to an average of 30 benefits of 5S implementation. In another minutes, which led to an annual labor-saving study by Deshpande (2015), the benefits of cost of$2000. 5S implementation included increases in In the study 5S Methodology Implementation productivity, reduction in equipment search in the Laboratories of an Industrial time, reduction in cost and inventory, Engineering University School, 5S was increase in workspace, well-defined implemented to optimize and improve the walkways, increased morale, and safetyof university engineering laboratories. participation of officers, staff, and workers Jiménez et al. (2015), justified the selection in continuous improvement. of an educational laboratory as suitable place for the implementation of 5S based on Conclusion teaching space for interaction with students, The results analyzed from the study supports the student productivity, and hands-on the stated hypotheses in the Introduction. 5S industrial experience. As such, the 5S was successfully implemented in the methodology was deployed in four surveying laboratory at WKU to improve laboratories; Sheet Metal Forming and efficiency, workspace, equipment search Cutting, Integrated Manufacturing Systems, time, work environment, and safety because Welding, and Metrology, over three months. of the active involvement of faculty. The outcome of 5S implementation was a Literature reinforces the need for active 30% reduction in practicums, improved management involvement for the successful control and maintenance of equipment, no implementation of 5S (Chitre, 2010; Douglas, laboratory accidents, reduced inventory and 2002; Naqvi, 2013). The results from the waste, clean environment, well-labeled study proved that 5S implementation within a equipment, and visual controls that university laboratory for standardization and communicated deviations or failures. This to provide students with an industrialized led to a cost reduction and a 25% increase in experience is justified. These findings available space. According to Jiménez et al. suggest that 5S can be successfully (2015), a new culture of commitment to implemented in other academic laboratories, continuous improvement was created among but may require a different plan. Since the participants (faculty, staff, and students) maintaining 5S, having a clean workspace, along with a detailed knowledge of available and clear aisle ways was an important factor resources in the laboratory. The next section for the surveying laboratory, the focus was on

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