From Chaos to Gemstone: A 5S Transformation in Jewellery Studio
A renowned jewellery studio was renowned for its exquisite craftsmanship. However, their workspace resembled a treasure trove gone haywire. Tools lay scattered, materials overflowed, and inspiration seemed lost amidst the clutter.
So, we took the challenge to transform it through the magic of workplace management.
Approach:
- Form a Cross-Functional Team & Structure:
- Assemble a cross-functional team with representatives from different departments and levels within the organization.
- Form the zone and zone leader structure for Implementation.
- Conduct a Workplace Assessment:
- Assess the current state of the workplace to identify areas that require improvement.
- Evaluate workspace layout, organization, cleanliness, and safety hazards.
- Identify opportunities for streamlining processes and optimizing workflow.
- Educate and Train Employees:
Sorting the Sparkles:
- The first step was a ruthless “gemstone purge.” Unnecessary tools, outdated materials, and half-finished projects were identified and either repurposed, donated, or sent to the “forgotten treasures” vault. Red tags, resembling discarded price tags, marked items on the chopping block.
Setting the Stage for Brilliance:
- Each tool found its designated haven, meticulously organized on shadow boards adorned with tool outlines. Gemstones were categorized by colour and type, residing in labelled containers that sparkled like miniature treasure chests. Workflows were streamlined, ensuring a smooth journey from raw materials to finished masterpieces.
Shining Like a Polished Gem:
- A daily “dusting of the diamonds” became a ritual. Spills were addressed with the swiftness of a jeweller polishing a tarnished gem. Each member became a guardian of their workspace, ensuring a constant state of sparkling cleanliness.
Standardizing the Sparkle:
- Procedures for every step of the jewellery-making process were documented, from metalworking techniques to gemstone selection. Visual aids and checklists adorned the walls, acting as silent guides for consistent quality and creative exploration.
Sustaining the Sparkle Forever:
- Regular “gemstone inspections” ensured adherence to the 5S principles. New artisans were welcomed with “5S bootcamp” training, and refresher sessions kept everyone sparkling with knowledge. Creativity thrived in a space where inspiration flowed freely, unhindered by the clutter of the past.
The Results: A Brighter Future for Sparkle & Co.
Reduced Time Waste:
- Before 5S: Average time spent searching for tools per day: 30 minutes per employee.
- After 5S: Average time spent searching for tools per day: 5 minutes per employee.
- Time Saved: 25 minutes per employee per day, translating to:
- Weekly: 125 minutes saved per employee
- Monthly: 500 minutes saved per employee
- Annually: 6,000 minutes saved per employee (equivalent to 100 hours)
Improved Product Quality:
- Before 5S: Average number of damaged pieces per month: 10
- After 5S: Average number of damaged pieces per month: 2
- Reduction in Damage: 80% decrease in damaged pieces
Increased Production Efficiency:
Increased Production: Potential for 33% increase in production output
Before 5S: Average production time per piece: 2 hours
After 5S: Average production time per piece: 1.5 hours
Production Time Reduction: 25% decrease in production time