Virat Services Case Study: Turning Chaos into Clarity - A Fabrication Unit's 5S Journey

 

Background

A mid-sized engineering and fabrication workshop was facing increasing operational challenges due to years of material accumulation and unstructured storage practices. Pipes, plates, structural sections, tools, scrap, and reusable materials were mixed together without zoning or identification.

This resulted in:

• Loss of usable space
• Difficulty locating materials
• Repeated purchase of already-available stock
• Safety hazard from unstable stacking
• No visibility of actual inventory
• Poor overall shopfloor discipline

The management engaged Virat Services for a practical, on-ground 5S systemization drive.

Objective of the 5S Campaign

The primary goals were:

• Remove all unwanted and obsolete materials
• Identify and segregate scrap
• Organize usable materials in a logical and safe manner
• Create clear storage zones
• Establish visual controls and labeling
• Provide clarity on available inventory
• Build a foundation for productivity and future QMS initiatives

Scope of Work Executed

S1 - SORT

• Complete clearing of major wall-side storage areas
• Identification and segregation of scrap and obsolete materials
• Recovery of several usable items that were previously unnoticed
• Preparation of a detailed Excel inventory with approximate quantities

S2 - SET IN ORDER

• Pipes arranged size-wise and category-wise
• Structural sections stacked safely and logically
• Clear allocation of zones of raw material, reusable stock, tools, and scrap
• Improved accessibility and safe stacking methods

S3 - SHINE

• Removal of dust, rust flakes, and accumulated debris
• Cleaning of racks, floors, and storage sections
• Clearing of congested corners and unused pockets

S4 - STANDARDISE

• Defined permanent zones for each material category
• Laminated signboards and instruction displays installed
• Section labels and area names pasted for easy identification
• Basic storage rules communicated to workers

Key Outcomes & Benefits Delivered

1. Complete visibility of available materials

-> Management now has documented stock data, enabling better planning.

2. Rediscovery of valuable materials

-> Several important materials that were previously unnoticed were identified and listed, enabling their use in upcoming projects.

3. Significant space recovery

-> Bulky, rusted, and obsolete materials occupying valuable floor space were identified and removed.

4. Improved material accessibility

-> Items can now be located quickly without unnecessary searching.

5. Safer working environment

-> Removal of unstable stacks and scattered scrap reduced accident risks.

6. Improved movement & workflow

-> Clear zones and better arrangement improved material handling efficiency.

7. Cost-saving potential

-> Visibility of inventory reduces unnecessary re-purchase of materials.

8. Enhanced shopfloor appearance

-> The workshop now looks structured, neat, and professionally managed.

9. Improved worker accountability

-> With zones and labels in place, responsibility becomes clear.

10. Strong base for system-driven growth

-> The workshop is now ready for structured processed, SOP implementation, and formal QMS adoption.

Sustainability Note

Prompt disposal of segregated scrap is essential to maintain the improved 5S condition and prevent re-cluttering. Continued adherence to zoning and storage discipline will ensure long-term benefits

Conclusion

This 5S campaign transformed a cluttered engineering workshop into a structured organized, and controlled working environment.

Beyond visual improvement, the initiative created operational clarity, space optimization, safety enhancement, and inventory visibility - establishing a strong foundation for productivity and future QMS initiatives.