Improvement through 7S Implementation Corp Limited.… · 1S – Sorting (Seiri)… • Total 535+...

Welspun Group | WCL Anjar | 7S Journey

Improvement through 7S ImplementationJuly 07, 2016


CONTENTS

1. Introduction

2. Present Business Scenario

3. Why 7S

4. The 7S Journey

5. Challenges - Implementation

6. Achievements

7. Conclusion & Way Forward

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WCL OVERVIEW

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Welspun is the largest big diameter linepipe manufacturing company in the world.Welspun has supplied pipes for the longestpipe line (Canada to US) for TransCanada,the heaviest pipe line for Persian Gulf andthe deepest pipe line for Gulf of Mexico.

Welspun Group | WCL Anjar | 7S Journey • Dammam: 0.35 MTPA• OD: 18”-100”• WT: 6-25.4 mm• Grade: Up to APIX80• Pipe Length up to

18m

• Dammam: 0.35 MTPA• OD: 18”-100”• WT: 6-25.4 mm• Grade: Up to APIX80• Pipe Length up to

18m

• Little Rock: 0.525 MTPA• OD: 6.625”-60”• WT: 4-25.4 mm• Grade: Up to APIX80• Pipe Length up to 24m

• Little Rock: 0.525 MTPA• OD: 6.625”-60”• WT: 4-25.4 mm• Grade: Up to APIX80• Pipe Length up to 24m

• Dahej, Anjar &Mandya: 1.775 MTPA

• OD: 1.25”-140”• WT: 2-43 mm• Grade: Up to APIX120• Pipe Length up to 18m

• Dahej, Anjar &Mandya: 1.775 MTPA

• OD: 1.25”-140”• WT: 2-43 mm• Grade: Up to APIX120• Pipe Length up to 18mIndia USA

SaudiArabia

GLOBAL CAPACITIES – HSAW, LSAW, HFW & COATING

Total Global Capacity - Coating

Capacity

32.05 million m2

Internal Coating

14 inch to 100inch

(InternalDiameter)

External Coating

2 inch to 120 inch(Outer Diameter)

Total Global Capacity 2.650 MTPA

Grade up to APIX120

HFWMTPA : 0.375OD: 1.25-20”WT : 2-14 mm

HSAWMTPA: 1.525OD: 18-140”WT: 5-27 mm

LSAWMTPA: 0.75OD: 16-60”WT: 6-43 mm

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MTPA – Million ton per annum


Journey of Welspun Corp Ltd….


Global Presence….


Present Business Scenario…

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In today’s competitive business scenario for sustainable growth ofany company … Optimum Resources Utilization Reduction of Wastages Equipment Effectiveness Inventory Control Employee Motivation Product Quality Improvement

To achieve…various lean tools are available

LeanTools

5S / 7STPM

KANBAN

Just InTime(JIT)

ANDON

SMED/ QCOVSM

OEE

TOC

Poka-Yoke

CellularManufacturing


Why 7S…

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• It is a foundation for Business ExcellenceReduces wasteLess searchingDecreased walking and motionReduced downtimeFewer accidentsFewer mistakesImproved process flowBetter use of space

Originator to other toolsVisual inventory replenishmentStandardized work procedureTotal Productive Maintenance (TPM)Setup reductionMistake-proofing

Creating aPleasant,

Well Organised,Clean &

Safe

workplace toincrease work efficiency & motivation


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Space constraints Poor quality of housekeeping Unsystematic disposal of discarded items Production crises and rigorous preparation prior to visit Low level of motivation Lesser machine efficiency

Why 7S… Scenario Before Initiation of 7S


- Inauguration by Top Management- Appointment of 7S Coordinator- Formation of 7S Organisation Structure- Road Map for Implementation- Training and Awareness to all Employees- Systematic Implementation in Phase Manner- Periodic Review by Top Management- Auditing System – Internal Audit & External Audit- Reward & Recognition

The Journey…

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Inaugural day 16th April 201415 Zones & 76 Sub-Zones

Class Room Training to All Employees Awareness Program at Plant Level

Inauguration & Awareness Campaign…

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1S – Sorting (Seiri)…

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Sorting Activities by Team

Unwanted items moved to Red tagarea with proper Tagging

7S Steering Committee visitat Centralized Red Tag Area


Before – After Before – After (Plant)

Before – After(Plant)

1S – Sorting (Seiri)…

• Total 535+ red tag items were identified.• Total space benefit of approx. 321 sq. meter by removing red tag items.• Recovered Rs 102 Lacs by selling red tag items.

• Total 535+ red tag items were identified.• Total space benefit of approx. 321 sq. meter by removing red tag items.• Recovered Rs 102 Lacs by selling red tag items. 13


2S – Systematic (Seiton)…

• Implemented “P E E P” Concept:Place for Everything & Everything at its Place

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3S – Shine (Seiso)…

• 3S SHINE Activities: To maintain overall cleanliness, “SHINE” activities are carried outperiodically in all the plants/zones as per 3S Cleaning Schedule.

• 3S Abnormality Status: Total 700+ abnormalities have been identified & corrected.

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4S – Standardisation (Seiketsu)…

• Formed 4S Committee for standardisation.• 104 Standards released for: Switch Identification,Pipe colour code, Place Demarcation & Identification,Safety, etc.

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5S – Safety…

• For effective implementation of 5S-Safety, an awareness training havebeen provided to all the employees.

• Near Miss and Unsafe Conditionswere identified by Zone Leaders/Members and rectified.

• Near Miss: 100+• Unsafe Conditions: 281+

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6S – Spirit…

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6S – Spirit…

Company Home


7S – Sustenance (Shitsuke)…

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Conducting Periodic Internal Audit

Effective implementation of audit findings

Adherence to the 3S Cleaning schedule

Rectification of abnormalities - 3S cleaning

Initiation of Tool Box Talk with 7S culture

Preparation of 7S Manual

Implementation of 7S Awareness – Induction

of new joinees

Review of 7S Effectiveness – WRM/ MIR/QRM

Launching of Reward & Recognition


7S – Sustenance (Shitsuke)… Tool box talk organised at mass level covering: SWA Oath Awareness followed by Question-answer session A note of appreciation

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Internal Audit System:7S – Sustenance (Shitsuke)…

Training to InternalAuditors

Preparation ofAudit Checklist –

For Offices & PlantsAudit Plan & Audit

Schedule Conduct an Audit

Countermeasureson Audit

ObservationsFollow up AuditClosure of Audit

36 employees were selected across the plant / functions and trained as Internal Auditors byour consultant for effective audits.

Internal Audit - Bimonthly basis External Audit - Half yearly basis

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4000+ nonconformities / observations / gaps were identified and rectified


Motivation through Recognition & Rewards… Held a competition for 7S Logo design Thursday selected for wearing 7S T-Shirts Organised a slogann competition Appealing slogans converted in posters and displayed in the plants Celebrated 7S Week full of fun & competitions

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Results…

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Total 321 sq. meter of office / plant space is vacated & being used for otherrequirements.

Total 84400 sq. meter of land is vacated & being used for plantation andgarden. 800+ trees are planted and 1200 sq. meter of lawn area is developed.

Significant improvement in Hygiene of canteen and common utilities. Remarkable visual & aesthetic improvement in entire WCL-Pipe Division, Anjar

plant. Overall awareness and sense of responsibility has been improved.


After completion of one year journey, following remark was maid during theaudit by one of the prestigious client “Welspun Anjar Unit has excelled inplant operations with the spirited employees and could see the visible changein the Unit”.

Anjar Unit has won: 'Certificate of Honour' and "Certificate of Appreciation" for 3.0

million plus accident free man-hours for the calendar year 2014 fromGujarat State Safety Council.

Prestigious “Gold Award” at National level organized, by GreentechFoundation for outstanding achievements in safety management byadopting best practices.

International Safety Award - 2016 with merit by British Safety Council. Top management has decided to implement 7S across the Welspun Group

having 20000+ employees after splendid achievement of Anjar unit. Top management launched the Swachh Welspun Abhiyan inline with Swachh

Bharat Abhiyan.

Results…

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Looking to the level of 7S implementation and degreeof employee involvement & enthusiasm WCLmanagement has put his step forward for TPMimplementation thru which 7S initiative will reaches tonew heights…..

Conclusion & Way Forward:

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Improvement through 7S Implementation Corp Limited.… · 1S – Sorting (Seiri)… • Total 535+...

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Transcript of Improvement through 7S Implementation Corp Limited.… · 1S – Sorting (Seiri)… • Total 535+...