Ebook Industrial engineering and operations management II: Part 2

Part 2 book "Industrial engineering and operations management II" includes content: Environmental, economic, and social impact of industrial symbiosis - methods and indicators review, continuous improvement in an industrial unit of the wood industry through kanban, evaluating the impact of 5S implementation on occupational safety in an automotive industrial unit.
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Ebook Industrial engineering and operations management II: Part 2 Evaluating the Impact of 5S Implementation on Occupational Safety in an Automotive Industrial Unit Joana P. R. Fernandes, Radu Godina and João C. O. Matias 1 Introduction In the wake of the competitive environment that organizations are facing, several companies are attempting to reinvent and adopt innovative practices that would allow them to surmount the various obstacles they encounter along the way [1]. One of the most popular practices adopted by the business world is the Lean Manufacturing, which is a result of the success story of Toyota. That despite the difficulties experi- enced at the time, it managed to promote sustainable and continuous growth through the maximization of the value of the product by through the reduction of the waste, through the maximization external and internal variability, among others [2–4]. Lean embraces several practices like just-in-time, quality systems, team work, among others [5]. “Lean is considered by several authors like a technique to reduce waste but the truth is lean maximizes product value through waste minimization” [6]. Even though the application of Lean principles brings numerous benefits to orga- nizations, the optimization of the productive process is not enough, there are other aspects to take into account. Among the several tools offered by lean, 5S as shown as J. P. R. Fernandes · J. C. O. Matias (B) DEGEIT, University of Aveiro, 3810-193 Aveiro, Portugal e-mail: jmatias@ua.pt J. P. R. Fernandes e-mail: fernandes.joana@ua.pt R. Godina Research and Development Unit in Mechanical and Industrial Engineering (UNIDEMI), Department of Mechanical and Industrial Engineering, Faculty of Science and Technology (FCT), Universidade NOVA de Lisboa, 2829-516 Caparica, Portugal e-mail: r.godina@fct.unl.pt J. C. O. Matias GOVCOPP, University of Aveiro, 3810-193 Aveiro, Portugal © Springer Nature Switzerland AG 2019 139 J. Reis et al. (eds.), Industrial Engineering and Operations Management II, Springer Proceedings in Mathematics & Statistics 281, https://doi.org/10.1007/978-3-030-14973-4_13 140 J. P. R. Fernandes et al. the most powerful and easy to use [7]. The 5S is one of the tools of Lean thinking that helps us create discipline culture, identify problems and generate opportunities for improvement. The 5S tool not only contributes to a more efficient work environment but also ensures improved occupational safety [8]. The 5S tool allows for developing a continuous improvement in the destination of the materials. This methodology improves the organizational environment, the productivity and consequently the motivation of the employees and is divided into 5 terms of Japanese origin: seiri, seiton, seiso, seiketsu and shitsuke and signify “Sort”, “Set in order”, “Shine/Sweep”, “Standardize”, and “Sustain/Self-discipline”, respectively. Each of these terms seeks to call the attention to a sense of responsibility [9–11]. The intensification of the workload could lead both to higher plant productivity. However, it could also lead to a stressful and deteriorating safety environment which, in turn, could have negative effects on factory employees [12]. Thus, recently, and as an evolution of 5S, a new label has emerged: 6S. The addition of safety implies the risk identification, it aims to develop work efficiency, quality of work, safety at work and optimize the discipline [13]. This technique can be labeled as 5S + the 6thS, which is the “S” of the occupational and safety standards. Such an approach could, in fact, improve the safety and at the same time the overall situation of the industrial unit as a result of an accurate 6S implementation [14]. The aim of this paper is to present a case of study in one industrial unit of one of Europe’s largest car producers and how the implementation of the 5S methodology can add not only to the improvement of the work environment but also if it could have a significant impact in ensuring the occupational safety. The remainder of this paper is organized as follows. In Sect. 2, the importance of improving the occupational safety is addressed. In Sect. 3, the implementation of 5S and 6S tools is described. Results are shown and discussed in Sect. 4. Finally, in Sect. 5, the conclusions are drawn. 2 The Importance of Improving the Occupational Safety In March of 2018, the International Organization for Standardization (ISO) released the standard ISO 45001: 2018—Occupational Health and Safety Management Sys- tems. This new standard is based on the same high-level structure on which safety systems (ISO 9001) and environmental (ISO 14001) are based, and it is intended to replace OHSAS 18001 [15–17]. The document provides a set of simple, effective processes and guidelines that are ready to improve occupational safety in global supply chains. This standard can be applied in both factories and in partners and production facilities, regardless of location. With this, it is expected to reduce the number of occupational injuries and diseases [18], which reached levels of serious concern [19]. An enterprise that seeks to be competitive, in these increasingly globalized mar- kets, needs to create an environment where the employee feels satisfied while per- Evaluating the Impact of 5S Implementation … 141 forming his duties. This increasingly requires the need to invest in programs and tools that prioritize safety and the quality of life at work [20]. Thus, there is an urgent necessity to employ any types of tools that could reduce the number of occu- pational hazards and consequently, possible injuries. Since 6S is transversal to all other steps of 5S, with this additional sixth “S” [21], the method also ensures the focus on the reduction ...