Helical Products Company of Santa Maria, CA is relatively new to lean concepts. The company
focuses on machined flexure products, such as u-joints and couplings, for various industries both
domestically and internationally. A recent interest in these lean concepts has generated discussion on to
where and exactly how the implementation of lean should begin. The location was decided on the
shipping department. The concern in this particular department is reducing shipping errors, producing
an efficient work environment, some small safety concerns and overall organization.
A diagnosis of the concerns proves that the shipping department is in need for 5S
implementation and error proofing. Based on gathered and researched information from various cases
studies, books, and journal entries on the topic a design will be created on how to implement 5S. The
research begins with an overview of what lean is. Included, some of the researched information will
feature a discussion on some success stories along with a discussion of why companies may fail at
implementation of lean. The research will then pinpoint to the topic of 5S with particular
supplementation of visual factory and error proofing concepts. The design will focus on molding these
concepts, which typically applied to production at the manufacturing level, to a shipping environment.
Many of these concepts were first introduced in IME 233 – Work Design and Measurement and theories
were briefly revisited in IME 410 – Production Systems and Control.
The catered design will take into account the input of employees both directly and indirectly
involved with the shipping department. A center of attention will be brought upon discovering areas
that produce waste according to the “8 wastes” concept of TPS, Toyota Production System, and overall
general Lean concepts. Safety although inherent to the 5S process will also be brought to attention,
especially in regards to shipping department activities. Consideration of similar cases will provide a set
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of countermeasures to predicted obstacles and issues that may occur. Overall the design will introduce
a set of recommendations on how to implement the 5S process as described above.
The report is organized in the form of literature review, 5S implementation Plan Design,
suggestions and recommendations, and lastly an appendix providing supplementary material. The
literature review will provide the background as discussed above and attempt to set the stage for the
ideas presented later in the report.