Improve the 5s Performance in an Assembly Plant Using Fuzzy Logic Based Modeling

Abstract — Nowadays in this dynamic and technological world, the secret of surviving for any kind of organization is to be competitive and pioneer in its products or services. One of the main ways to succeed is continuous improvement and increasing the quality of product or service. However, there is lack of knowledge in some improving methods and tools like 5S and the challenge is much greater. This 5S system which is a component of lean manufacturing helps organize a workplace efficiently. A 5S audit was designed which enabled each zone head to identify the potential level of quality improvement and at the same time analyze the ability and weakness of each zone in the division. Most measures of 5S are described subjectively by linguistic terms which are characterised by ambiguity and multi-possibility, thus, using the conventional approaches to 5S assessment is not effective whereas fuzzy logic provides a useful tool for dealing with decisions in which the phenomena are imprecise and vague. A 5S assessment model was designed and evaluated, followed by, weighing up the same using fuzzy logics. After determining the 5S level at the 5 zones, the importance indexes of various 5S attributes were found. Various proposals for 5S improvement were suggested based on the experiences of the conduct of the project. These proposals after implementation lead to enhancement of quality and thereby increase in the efficiency of the organisation