Training Topic: 5S And Kaizen Management

Training Date: 22-11-2023

Team 1.

Person Name: M. Imran & Muzammil Hussain (Powerhouse & Utility)

Allocated Visit Area: DPM Department

Observation:

1. Found the moisture in air.

2. Found the air buffer tank not ground with foundation.
3. Not safety extinguishers installed in proper way.

Corrective Action:

1. Installed auto drain valve bottom side of air buffer tank and clear the moisture from
air.
2. Advise to related person to ensure permanent ground the buffet tank with Rawal bolts.
3. Advise to related person to ensures that safety equipment installed in proper way.

Team 2.

Person Name: Syed Sajjad Naqvi, Sami Ullah (Glaze Line)

Allocated Visit Area: Lab & QC Department

Problems and Corrective Action:

1. House-keeping: there is not proper management for cleaning and tool handling, the
things are scattered everywhere.
2. Safety precautions: while using the machine, there should be adopted such
precautions that does not cause of dust or environmental hazards. There is no safety
for crusher, so is can also cause of accident.
3. There is not proper ventilation in lab which cause of breath problem, so there should
be exhaust fans for proper ventilation.
4. The ceiling is damaged and lights are not working conditions.
5. Sample of raw materials, biscuit and tiles are scattered in the lab, there should be
proper space to store the biscuits and tiles of samples and also for raw materials
Sample
Team 3.

Person Name: Rana Karamat, Umair Haseeb, Ali Raza (Lab /R & D)
Allocated Visit Area: Glaze Line Department.

Problem:

1. Roller Pulley’s belts rotating without safety cover

2. Improper water segregation
3. Housekeeping not good
4. Irrelevant thing found at department like AC/ water cooler etc.
5. Glaze line with wall distance is very narrow from designer office to lab.
6. Glaze shifting hose pipe broken resulting wastage of glaze.

Observation:

1. Due to less space

2. Negligence
3. Civil work required
4. Hose pipe old /low quality
5. Untrained helpers
6. Improper things placement

Corrective Action:

1. Indication tag for safety

2. Safety measures required
3. Proper tie the electric wires hanging
4. Civil work need modification for proper water segregation
5. Replacement of hose pipe with good quality material’s
6. Other things must be lift and place at relevant area.
7. Training and work instructions must be identified.

Team 4.

Person Name: Irfan Ahmad, Mubasher Hussain (Sorting & Packing Line)

Allocated Visit Area: Body Preparation Department.

Problems:

1. Spray dryer safety barriers issue

2. Ball mill gear barriers issue
3. Spray dryer chain cover issue
4. Dust exhaust fan out of order
5. Oil Drum and tools placed out of order.
6. Floor was dust with oil and powder

Corrective Action:

1. Safety barriers must fix.

 2. Exhaust fan must repair
3. Tools and other materials must be place in order
4. Need to keep the floor clean
5. Danger area must mention.
6. Safety Signs must be hanged on restriction area.
Team 5.

Person Name: Abdul Hafeez, Qamar Uz Zaman (Electrical)

Allocated Visit Area: Press Department.

Problem:

1. Unhealthy working environment or dusty

2. Gear oil leaked and dropped at ground

Reason:

3. Due to pressing Powder

4. Storage trays leaked /over filling

Corrective Action:

5. Increase capacity of de-dusting unit.

6. Repair /Change oil storage trays
7. Fill gear oil below high-level indication.
Team 6.

Person Name: Shahid Nazir, Farhan Ahmad (Polish & Squaring Line)

Allocated Visit Area: Store Department.

Problems:

1. Store location issue

2. Temperature issue
3. Tag indication
4. Store items mix not proper segregate
5. Lift Problem

Reason:

1. Store location on height, it causes difficult to bring massive materials.

2. Rubber materials melt
3. Time waste.
4. Materials place outside the store area.

Correction Action:
 1. Store should be on floor
2. Temperature should be maintained
3. Proper inspection required
4. Proper lifting from height.
5. Materials warn out
Team 7.

Person Name: Hasham Muzammil, Muhammad Kamran (DPM)

Allocated Visit Area: Sorting & Packing line and Qualitron Machine Department.

Problem:

1. Dirty water on bottom of tile after squaring resulting in damaging of belts & Bearings.
2. Oil leakage from gear
3. Motor & gear chain is not covered

Observation:

1. Proper cleaning system is not present and using dirty water

2. Gear oil seals are damaged
3. Unavailability of covering sheet or not installed after maintenance.

Corrective Action:

1. Blower and cleaning brushes can be installed to clean water

2. Maintenance of gear oil seals
3. Install or cover the chain to avoid accident.
Team 8.
Person Name: Fakhar Mahmood (Press/R & D)

Allocated Visit Area: Mechanical Workshop and scrape yard.

Problem:

1. Equipment not in order

1. No proper Lighting
2. Noise Pollution
3. Oily Floor
4. Mixed all machines
5. Under maintenance parts are not sorted
6. No working safety
7. Scrap yard area is undefined
8. Lathe machine moving parts could be a safety risk

Reason:
 1. Staff is not well trained, no proper racks
2. Lights quantity is not enough
3. Congested area and machines installation plan not proper.
4. No proper rack for parts segregation
5. Lathe machine moving parts are not covered
6. No safety helmets, no welding goggles, no gloves
7. Nom wall around scrap yard for identification and prevent theft.

Corrective Action:

1. Need proper training of staff and make racks

2. Avail more lights to install for significant visibility
3. Walls and roof should be proper isolated for prevent noise
4. Repairing gearing and oily equipment should have a separate place
5. Area of workshop must be wider
6. Need enough rack and tags
7. All machinery must be covered
8. Arrange all safety equipment and avoid accident
9. Build a proper brick safety wall and gate with lock and key of scrape yard

Team 9.
Person Name: M. Saleem, Faiz Rasool (Kiln)

Allocated Visit Area: Polish & Squaring Line Department.

Problem and Corrective Action:

1. Not tie extra rack /belt

2. Undefined sitting areas
3. Need to cover an electrical wire
4. Need to place abrasive properly
5. Unnecessary use of water
6. Mechanical tools not in order

Team 10.
Person Name: Suleman Khan, M. Sibtain Ahmad (Store, Account)

Allocated Visit Area: Polish & Squaring Line Department.

Problem:

1. Used material placed with unused material

2. Excessive noise pollution
3. Breakage of belt on floor
4. No safety at all
Reason:

1. No proper placement of materials

2. No standard size of tile
3. Variation in tile thickness resulting in breakage
4. Water includes dust materials
5. No provision of safety measures

Corrective Action:

1. RO plant must improve the quality of water

2. Provision of air bags, gloves, shoes etc.
3. Used materials must transfer to scrape bins
4. Need proper maintenance/ house keeping
5. No vibration in the head plus improve the tile strength resulting less breakage.

Team 11.
Person Name: M. Awais, M. Tayyab (Qualitron machine)

Allocated Visit Area: Glaze Preparation Department.

Problems
1. Wire-carrying railing of Chain hoist machine is not proper which is leading to
electrical wires damage.
2. Electrical wires of machines are not managed at all. Electrical wires are lying on floor
with their naked joints. The dressing of electric wires is very poor and unsafe.
This problem is so severe that it can cause serious accidents.
3. Workers are not wearing safety gears like shoes, gloves etc. while doing heavy duty
work.
Observed Reasons
1. Wire-Carrying railing of chain hoist machine is not properly manufactured causing
electric wire damages.
2. Negligence of electrical department.
3. The lack of safety education of humans and machines.

Corrective Actions
1. Need to widen the wire-carrying railing of chain hoist machine. Also need to fix the
turning angle of path of chain hoist machine.
2. Need to properly dress the electric wires. Use cable trays. Follow standard procedures
for electric wire joints for better human as well as machine safety.
3. Need to conduct safety education training sessions for better safety awareness.
Team 12.
Person Name: M. Yamin, M. Zeeshan (GPD)

Allocated Visit Area: Warehouse Department.

Observations:
1. Safety issues found in different expects, Fire Exiguousness placements & quality
checking, Emergency floor Marking didn’t find, if any incident happen, Proper Tools
not available for heavy product loading.
2. Insufficient Storage Space Issue.

Corrective Actions:
 Requested to concerned authorities to ensure the Safety equipment’s. (Safety Shoes,
Helmets, Gloves & visible jackets as well & place the required safety equipment’s in
warehouse to avoid any uncertainty).

 Warehouse have capacity to store the commodity of 160,000 Sqm Approx. And when
the stock Exceed this limit then unfortunately we need to shift outside area and
production hall as well. which may the cause of product breakage during handling
especially. So, its requested to concerned authorities to settle this issue on top priority
basis.

Team 13.
Person Name: Sikandar Sayyed, M. Adnan(Warehouse)

Allocated Visit Area: KILN Department.

Observations:
1. Control Room in dusty Condition.
2. Kilin Heat Control Glass Wool sheet quality Need to Improve.
Corrective Actions:
 Requested to concerned authorities to ensure the proper cleaning in Kilin
control Room, because the equipment is very sensitive & expensive as well.
Make a cleaning Check list & ensure on daily bases by Kilin Manager.
  Requested to concerned authorities, Kilin Heat Control Glass Wool sheet
quality Need to Improve to control Heat loses.

Team 14.
Person Name: M. Aasham, M. Hasan (BPD)

Allocated Visit Area: Powerhouse & Utility Department.

Observations:
1. Found the poor condition of press filters.
2. Found the poor quality of suction air for air compressors.
3. Found the improper noise reduction arrangements in Engine Room.
4. Found the improper water proofing in the roof and walls of LT & HT Panel Rooms.
Corrective Actions:
1. Change the membranes of press filter as the membranes are chocked.
2. Advised to install the filters at the inlet of air suction to ensure best quality air
for compressors suction.
3. Advised to make proper arrangements to reduce the noise level to ensure the safety
of workers inside engine room.
4. Advised to make better water proofing arrangements in the walls and roof of the HT
& LT panel’s room to save the equipment from damages.

Team 15.
Person Name: Arshad Abbas, Atta Ur Rahman (Mechanical)

Allocated Visit Area: HR & Admin Block

Observations:

 Unwanted files/documents scattered on HR & Admin desk or table

 Delayed caption of fire extinguisher r stock.
Corrective Actions:
 Purchaser is instructed to improve the speed of collection and delivery of fire
extinguisher.
 Proper files are maintain in cupboard with day to day.