Analysis of 5S Implementation Lapses in PFC Lines: A Case Study from SEIPL plant

The 5S methodology consists of the 5 S’s – Sort(Seiri), Set-in-order(Seiton), Shine(Seiso), Standardize(Seiketsu) and Sustain(Shisuke). This 5S methodology is widely adopted in lean manufacturing to enhance workplace organization, efficiency, and safety. But the complete impact of 5S is not achieved because of the lapses in implementing 5S. In this paper, a detailed study of the PFC (Power Factor Correction) lines of the Schneider Electric plant has been conducted to determine and examine the phases where 5S practice were not successfully implemented. By the systematic observation, root cause analysis, and operator comments, critical lapses were classified and resolved with action-oriented recommendations. This research enhances the maintenance of 5S standards via a duplicable framework to conduct periodic audits and ongoing improvements.