Welspun Group | WCL Anjar | 7S Journey
Improvement through 7S ImplementationJuly 07, 2016
Welspun Group | WCL Anjar | 7S Journey
CONTENTS
1. Introduction
2. Present Business Scenario
3. Why 7S
4. The 7S Journey
5. Challenges - Implementation
6. Achievements
7. Conclusion & Way Forward
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Welspun Group | WCL Anjar | 7S Journey
WCL OVERVIEW
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Welspun is the largest big diameter linepipe manufacturing company in the world.Welspun has supplied pipes for the longestpipe line (Canada to US) for TransCanada,the heaviest pipe line for Persian Gulf andthe deepest pipe line for Gulf of Mexico.
Welspun Group | WCL Anjar | 7S Journey • Dammam: 0.35 MTPA• OD: 18”-100”• WT: 6-25.4 mm• Grade: Up to APIX80• Pipe Length up to
18m
• Dammam: 0.35 MTPA• OD: 18”-100”• WT: 6-25.4 mm• Grade: Up to APIX80• Pipe Length up to
18m
• Little Rock: 0.525 MTPA• OD: 6.625”-60”• WT: 4-25.4 mm• Grade: Up to APIX80• Pipe Length up to 24m
• Little Rock: 0.525 MTPA• OD: 6.625”-60”• WT: 4-25.4 mm• Grade: Up to APIX80• Pipe Length up to 24m
• Dahej, Anjar &Mandya: 1.775 MTPA
• OD: 1.25”-140”• WT: 2-43 mm• Grade: Up to APIX120• Pipe Length up to 18m
• Dahej, Anjar &Mandya: 1.775 MTPA
• OD: 1.25”-140”• WT: 2-43 mm• Grade: Up to APIX120• Pipe Length up to 18mIndia USA
SaudiArabia
GLOBAL CAPACITIES – HSAW, LSAW, HFW & COATING
Total Global Capacity - Coating
Capacity
32.05 million m2
Internal Coating
14 inch to 100inch
(InternalDiameter)
External Coating
2 inch to 120 inch(Outer Diameter)
Total Global Capacity 2.650 MTPA
Grade up to APIX120
HFWMTPA : 0.375OD: 1.25-20”WT : 2-14 mm
HSAWMTPA: 1.525OD: 18-140”WT: 5-27 mm
LSAWMTPA: 0.75OD: 16-60”WT: 6-43 mm
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MTPA – Million ton per annum
Welspun Group | WCL Anjar | 7S Journey
Journey of Welspun Corp Ltd….
Welspun Group | WCL Anjar | 7S Journey
Global Presence….
Welspun Group | WCL Anjar | 7S Journey
Present Business Scenario…
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In today’s competitive business scenario for sustainable growth ofany company … Optimum Resources Utilization Reduction of Wastages Equipment Effectiveness Inventory Control Employee Motivation Product Quality Improvement
To achieve…various lean tools are available
LeanTools
5S / 7STPM
KANBAN
Just InTime(JIT)
ANDON
SMED/ QCOVSM
OEE
TOC
Poka-Yoke
CellularManufacturing
Welspun Group | WCL Anjar | 7S Journey
Why 7S…
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• It is a foundation for Business ExcellenceReduces wasteLess searchingDecreased walking and motionReduced downtimeFewer accidentsFewer mistakesImproved process flowBetter use of space
Originator to other toolsVisual inventory replenishmentStandardized work procedureTotal Productive Maintenance (TPM)Setup reductionMistake-proofing
Creating aPleasant,
Well Organised,Clean &
Safe
workplace toincrease work efficiency & motivation
Welspun Group | WCL Anjar | 7S Journey
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Space constraints Poor quality of housekeeping Unsystematic disposal of discarded items Production crises and rigorous preparation prior to visit Low level of motivation Lesser machine efficiency
Why 7S… Scenario Before Initiation of 7S
Welspun Group | WCL Anjar | 7S Journey
- Inauguration by Top Management- Appointment of 7S Coordinator- Formation of 7S Organisation Structure- Road Map for Implementation- Training and Awareness to all Employees- Systematic Implementation in Phase Manner- Periodic Review by Top Management- Auditing System – Internal Audit & External Audit- Reward & Recognition
The Journey…
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Welspun Group | WCL Anjar | 7S Journey
Inaugural day 16th April 201415 Zones & 76 Sub-Zones
Class Room Training to All Employees Awareness Program at Plant Level
Inauguration & Awareness Campaign…
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Welspun Group | WCL Anjar | 7S Journey
1S – Sorting (Seiri)…
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Sorting Activities by Team
Unwanted items moved to Red tagarea with proper Tagging
7S Steering Committee visitat Centralized Red Tag Area
Welspun Group | WCL Anjar | 7S Journey
Before – After Before – After (Plant)
Before – After(Plant)
1S – Sorting (Seiri)…
• Total 535+ red tag items were identified.• Total space benefit of approx. 321 sq. meter by removing red tag items.• Recovered Rs 102 Lacs by selling red tag items.
• Total 535+ red tag items were identified.• Total space benefit of approx. 321 sq. meter by removing red tag items.• Recovered Rs 102 Lacs by selling red tag items. 13
Welspun Group | WCL Anjar | 7S Journey
2S – Systematic (Seiton)…
• Implemented “P E E P” Concept:Place for Everything & Everything at its Place
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Welspun Group | WCL Anjar | 7S Journey
3S – Shine (Seiso)…
• 3S SHINE Activities: To maintain overall cleanliness, “SHINE” activities are carried outperiodically in all the plants/zones as per 3S Cleaning Schedule.
• 3S Abnormality Status: Total 700+ abnormalities have been identified & corrected.
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Welspun Group | WCL Anjar | 7S Journey
4S – Standardisation (Seiketsu)…
• Formed 4S Committee for standardisation.• 104 Standards released for: Switch Identification,Pipe colour code, Place Demarcation & Identification,Safety, etc.
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Welspun Group | WCL Anjar | 7S Journey
5S – Safety…
• For effective implementation of 5S-Safety, an awareness training havebeen provided to all the employees.
• Near Miss and Unsafe Conditionswere identified by Zone Leaders/Members and rectified.
• Near Miss: 100+• Unsafe Conditions: 281+
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Welspun Group | WCL Anjar | 7S Journey
6S – Spirit…
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Welspun Group | WCL Anjar | 7S Journey
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6S – Spirit…
Company Home
Welspun Group | WCL Anjar | 7S Journey
7S – Sustenance (Shitsuke)…
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Conducting Periodic Internal Audit
Effective implementation of audit findings
Adherence to the 3S Cleaning schedule
Rectification of abnormalities - 3S cleaning
Initiation of Tool Box Talk with 7S culture
Preparation of 7S Manual
Implementation of 7S Awareness – Induction
of new joinees
Review of 7S Effectiveness – WRM/ MIR/QRM
Launching of Reward & Recognition
Welspun Group | WCL Anjar | 7S Journey
7S – Sustenance (Shitsuke)… Tool box talk organised at mass level covering: SWA Oath Awareness followed by Question-answer session A note of appreciation
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Welspun Group | WCL Anjar | 7S Journey
Internal Audit System:7S – Sustenance (Shitsuke)…
Training to InternalAuditors
Preparation ofAudit Checklist –
For Offices & PlantsAudit Plan & Audit
Schedule Conduct an Audit
Countermeasureson Audit
ObservationsFollow up AuditClosure of Audit
36 employees were selected across the plant / functions and trained as Internal Auditors byour consultant for effective audits.
Internal Audit - Bimonthly basis External Audit - Half yearly basis
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4000+ nonconformities / observations / gaps were identified and rectified
Welspun Group | WCL Anjar | 7S Journey
Motivation through Recognition & Rewards… Held a competition for 7S Logo design Thursday selected for wearing 7S T-Shirts Organised a slogann competition Appealing slogans converted in posters and displayed in the plants Celebrated 7S Week full of fun & competitions
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Welspun Group | WCL Anjar | 7S Journey
Results…
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Total 321 sq. meter of office / plant space is vacated & being used for otherrequirements.
Total 84400 sq. meter of land is vacated & being used for plantation andgarden. 800+ trees are planted and 1200 sq. meter of lawn area is developed.
Significant improvement in Hygiene of canteen and common utilities. Remarkable visual & aesthetic improvement in entire WCL-Pipe Division, Anjar
plant. Overall awareness and sense of responsibility has been improved.
Welspun Group | WCL Anjar | 7S Journey
After completion of one year journey, following remark was maid during theaudit by one of the prestigious client “Welspun Anjar Unit has excelled inplant operations with the spirited employees and could see the visible changein the Unit”.
Anjar Unit has won: 'Certificate of Honour' and "Certificate of Appreciation" for 3.0
million plus accident free man-hours for the calendar year 2014 fromGujarat State Safety Council.
Prestigious “Gold Award” at National level organized, by GreentechFoundation for outstanding achievements in safety management byadopting best practices.
International Safety Award - 2016 with merit by British Safety Council. Top management has decided to implement 7S across the Welspun Group
having 20000+ employees after splendid achievement of Anjar unit. Top management launched the Swachh Welspun Abhiyan inline with Swachh
Bharat Abhiyan.
Results…
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Welspun Group | WCL Anjar | 7S Journey
Looking to the level of 7S implementation and degreeof employee involvement & enthusiasm WCLmanagement has put his step forward for TPMimplementation thru which 7S initiative will reaches tonew heights…..
Conclusion & Way Forward:
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Welspun Group | WCL Anjar | 7S Journey
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