Virat Services Case Study: 5S Created Wonders and BIG PROFIT for Our Client Rashminbhai, a Brass Parts Factory Owner in Jamnagar

The name used "Rashminbhai" is fictional and not describing any individual

Scene: Rashminbhai’s brass factory in Jamnagar – dusty floor, hundreds of gunny bags (bachkas), cluttered paths, and confused workers.

Virat (Consultant):
“Rashminbhai, to be very honest, I don’t know where to start with QMS implementation here. This place is like a brass jungle.”

Rashminbhai (Smiling, a little embarrassed):
“Bhai, I know… even I get confused finding things here sometimes. But this is how it has been for years.”

Virat:
“Then let’s not talk QMS yet. First, let’s clean the jungle. Let’s bring 5S to life.”

Day 1: The 5S Campaign Kick-off

Virat gathered all workers—aged mistrys, energetic boys, and shy clerks—under one roof.

Virat (to everyone):
“Today, we only talk about the first S – Sort. Let’s separate what we really use… from what we don’t.”

Worker:
“But Sir, everything looks same… all in bachkas.”

Virat:
“Good point! So from tomorrow, we’ll use color-coded gunny bags to differentiate.”

Color Coding System Introduced

• 🔵 Blue: Finished goods ready for dispatch

• 🔴 Red: Rejections

• 🟡 Yellow: Semi-finished goods

• 🟢 Green: Unchecked items

Virat:
“Post this chart on the wall. So even if a worker can’t read, he can still understand by color.”

The Discovery: Hidden Treasure in "Unknown" Goods

As part of S1 - Sort, Virat introduced a "Mystery Category":

-> Useful – Not Useful – Don’t Know What It Is

The staff collected 1,500 kg of brass parts under “Don’t Know”.

Virat:
“Rashminbhai, see this pile? These are goods that nobody knows about. Kept for rework, return, future use… and forgotten.”

Rashminbhai (shocked):
“That’s almost ₹7.5 lakhs worth brass at today’s rate! Just lying dead!”

Visible & Measurable Improvements Within 30 Days

Problem Before 5S	Result After 5S
10–15 minutes wasted in finding the right bachka	Search time reduced to < 1 minute using color codes
1–2 incidents/month: staff tripping on bags or slipping on swarf	ZERO injuries in 3 months post-cleanup
4–5 wrong dispatches/year due to mix-ups	ZERO dispatch errors in last 6 months
₹7.5 lakhs blocked brass stock lying unknown	Sorted, remelted, and reused – SAVINGS RECOVERED
Frequent store congestion	40% floor space freed up for smooth operations

Rashminbhai’s Realisation (2 Months Later)

Rashminbhai:
“Virat, pehla to hu hamesha bharela store joine bhadkato hato… but now, it's a pleasure to walk in.”

Virat (smiling):
“And not just that… your factory looks 20% bigger now without adding a single square foot!”

Rashminbhai:
“You made my place shine, and saved lakhs. 5S should be taught in schools, not just factories!”

Conclusion: 5S Wasn’t Just Cleaning – It Was Profit Creation

What started as a cluttered, confused space is now a streamlined, safe, and productive unit.
Virat didn’t start with fancy tools, software, or certifications.
He started with 5S, and it brought:

✅ ₹7.5 lakhs+ brass recovered
✅ 40% space optimization
✅ 100% traceability
✅ 0 dispatch errors
✅ Better morale & safety
✅ A new mindset in workers