POLITEKNIK MERLIMAU
MECHANICAL ENGINEERING DEPARTMENT
DJF41052 – MANUFACTURING SYSTEM
PROJECT LEAN SYSTEM
SESSION: 2 2022/2023
STUDENTS NAME:
NUR AIMY SUFEA BINTI MARZUKI / 14DTP21F1069
NUR FARISHA NAJWA BINTI RUSLAN / 14DTP21F1006
MUHAMMAD DANISH ASYRAF BIN ROSLAN / 14DTP21F1058
MUHAMMAD AMEER AL-HASSANI BIN SZUL-FICAR / 14DTP20F1056
LECTURER NAME:
PUAN AZRIN BINTI NOZMI
Prepare your technical report as a proposal to the Board of Director. The content
that needs to be include in your report are:
1. Introduction - Company background
Our group has discussed choosing the company MU Digital Foto Studio, which is a
store selling writing tools and telephone accessories. The store also offers a photostat
service and prints passport photos and family photos. The store has been operating
for 11 years, established in 2012. The company has two employees with their own
families. There are a number of problems they have faced that have never been
resolved until now.
Knowing how to organise a small store is one of the most important things for the store
owner. If you provide a variety of requirements so that a small shop does not make the
customer feel uncomfortable, then you must organise the small store well. Believe it
or not, a more organised small store will make customers feel more comfortable and
want to buy back in the store. Managing a small store has its own challenges because
the space is limited. However, we must place the goods well and fit them so that they
are easily accessible and make customers comfortable.
Therefore, our goal is to solve the problems faced by the MU Digital
Photo Studio Company.
2. Background of research - Major problem they faced and impact of the
problems to the company
There are a number of problems in the store, including a shortage of employees.
Among the consequences of a shortage of employees is that the quality of customer
service decreases. With a smaller number of employees, service to customers may
become slower or less efficient. Customers have to wait longer to get the service. This
can lead to customer dissatisfaction and potentially
reduce the number of customers coming to the store.
Next, if there is a delay in completing work, for example,
if there is a shortage of workers, work in the photostat
store may not be resolved quickly. This can be a
problem, especially if there are customers who need a
photocopy or photostat in a short time for vital needs.
Workers also feel overloaded on themselves; they have
to deal with more work and may feel overly depressed
or stressed.
The second problem their company faces is the
narrow room. The narrow space in the store can have
several consequences that affect the comfort and
efficiency of work. The limitations of space can make
customers feel uncomfortable and distracted. In
addition, the presence of a large number of people in
a narrow space can interfere with concentration due
to the existence of noise and disturbance from the
interaction of others. Safety and security can also be
threatened due to the high risk of accidents or injuries
due to space constraints. In addition, narrow spaces
can also hamper the efficiency of work due to limited equipment and available
workspaces.
The third problem is that there is no storage space.
When a store does not have adequate storage space
for its stock of goods, a number of negative
consequences can arise. Space constraints become a
major problem when a shortage of storage space results
in an empty and messy working space. In addition, there
may be a risk of loss of stock that may result from theft.
The efficiency of work is also disrupted due to the time
wasted finding and arranging the necessary items. In
addition, this situation also potentially reduces hygiene
and creates a risk of damage to the goods.
The next issue is the arrangement of non-strategic items. As a result, customers may
have trouble finding the necessary equipment and materials. Workers and sellers also
spend excessive time searching for and returning items.
Lastly, poor ventilation in the store As a result, it can cause the accumulation of dust
and an unpleasant odour. This can cause employees and customers to feel insecure
and have health problems such as eye irritation, nose congestion, or allergies.
3. Analysis - Suggest the most suitable lean technique, and briefly describe the
improvement once applying lean technique. Include together with analysis on
previous and new record achievement.
The 5S method, which stands for Sort, Set in Order, Shine, Standardize, and Sustain,
involves organizing and standardizing the workplace to eliminate waste and improve
productivity. Companies have reported reduced costs, improved quality, increased
safety, and better employee morale by following the 5S approach. Each step of the 5S
process can benefit organizations. After looking into it, we discovered that this store
had several issues that can be resolved through 5s. One of them is that the products
in the shop will be reorganised using the Set in Order (Seiton) method, preventing
issues with accessibility between the objects, such as the location of the file shelves
that are blocked by the printer. Additionally, Sort (Seiri) can maximise storage space
utilisation, resolving the issue of
a narrow store caused by the
placement of non-strategic
stuff. The next step is
Standardise (Seiketsu), which
combines the placement of all
the items in the store as they
have been organised based on
the type of brand, colour, use,
and other factors. The Shine
(Seiso) method is then used to
Figure 1: Explain about 5S
prevent the interior of the shop from becoming dirty from different sorts of dust, such
as spider webs and other debris. Sustain (Shitsuke), the final option, will keep the 5s
that have been implemented in the store. Overall, implementing the 5s method can
greatly improve the functionality and appearance of the store. By using Seiton, Seiri,
Seiketsu, Seiso, and Shitsuke, the store can be reorganised, maximise storage space,
maintain cleanliness, and sustain the improvements made. These changes will
ultimately benefit both the employees and customers of the store. As a more organised
and cleaner store can lead to increased productivity and customer satisfaction.
Additionally, implementing the 5s method can also promote a culture of continuous
improvement and efficiency within the store.
4. Discussion - Impact/result
This lean system such as 5S will improve the overall efficiency of the shop, as workers
are able to focus on their tasks without being hindered by clutter or disorganization.
Additionally, implementing the 5S methodology can lead to a reduction in workplace
accidents and injuries, as hazards are identified and eliminated. This can result in a
safer work environment for employees, which can lead to increased job satisfaction
and retention. Overall, the impact of 5S on a company can be significant, improving
productivity, safety, and employee morale. For instance,
a manufacturing company that implemented 5S saw a
20% increase in productivity and a 30% reduction in
accidents within the first year. The employees were able
to complete their tasks more efficiently, with less time
spent searching for tools or materials, and the
elimination of hazards made the workplace safer for
everyone. This led to a happier and more motivated
workforce, which ultimately improved the company's
bottom line. Implementing a lean system such as 5S
can have a positive impact on a company's productivity, safety, and employee morale.
By eliminating clutter and disorganization, workers are able to focus on their tasks and
complete them more efficiently. This can lead to a reduction in workplace accidents
and injuries, resulting in a safer work environment for employees. Ultimately, the
implementation of 5S can improve a company's bottom line by increasing productivity
and employee satisfaction.
5. Conclusion
The MU Digital Photo Studio is a store selling writing tools, telephone accessories,
photostat service, and prints passport photos and family photos. It has been operating
for 11 years and has two employees with their own families. There are a number of
problems in the store, including a shortage of employees, which can lead to customer
dissatisfaction and potentially reduce the number of customers coming to the store.
Additionally, if there is a delay in completing work, work in the photostat store may not
be resolved quickly, which can be a problem for customers who need a photocopy or
photostat in a short time. The most important details in this text are the three main
problems facing a store.
The first is the narrow room, which can make customers feel uncomfortable and
distracted, interfere with concentration, and threaten safety and security. The second
problem is the lack of storage space, which can lead to an empty and messy working
space, loss of stock, and poor ventilation. The third problem is the arrangement of non-
strategic items, which can cause customers to have trouble finding the necessary
equipment and materials, and poor ventilation can cause dust and an unpleasant
odour. The 5S method, which stands for Sort, Set in Order, Shine, Standardize, and
Sustain, involves organizing and standardizing the workplace to eliminate waste and
improve productivity. Companies have reported reduced costs, improved quality,
increased safety, and better employee morale by following the 5S approach.
This store had several issues that could be resolved through 5S, such as reorganising
products, maximising storage space utilisation, standardising items based on brand,
colour, use, and other factors, and preventing the interior of the shop from becoming
dirty. 5S is a lean system that can improve efficiency, safety, and employee morale. It
eliminates clutter and disorganization, allowing workers to focus on their tasks and
complete them more efficiently. This can lead to a reduction in workplace accidents
and injuries, resulting in a safer work environment for employees. Overall, 5S can
improve a company's bottom line by increasing productivity and employee satisfaction.
6. REFERENCES
• Lean manufacturing - Wikipedia. (2021, June 1). Lean Manufacturing -
Wikipedia. https://en.wikipedia.org/wiki/Lean_manufacturing
In-Text Citation: (Lean Manufacturing - Wikipedia, 2021)
• 5S – Lean Manufacturing and Six Sigma Definitions. (n.d.). 5S – Lean
Manufacturing and Six Sigma Definitions.
https://www.leansixsigmadefinition.com/glossary/5s/
In-Text Citation: (5S – Lean Manufacturing and Six Sigma Definitions, n.d.)
• http://esearchgate.net/publication/341232776_Case_Study_on_Lean_Manufa
cturing_System_Implementation_in_Batch_Type_Manufacturing_Industry.
(n.d.).
http://esearchgate.net/publication/341232776_Case_Study_on_Lean_Manufa
cturing_System_Implementation_in_Batch_Type_Manufacturing_Industry
• Applying 5S in the Manufacturing Industry | Lean Production. (n.d.). Applying
5S in the Manufacturing Industry | Lean Production.
https://www.leanproduction.com/5s/
• Applying 5S in the Manufacturing Industry | Lean Production. (n.d.). Applying
5S in the Manufacturing Industry | Lean Production.
https://www.leanproduction.com/5s/
