AN ANALYTICAL STUDY ON CO-RELATION BETWEEN 5'S AND PRODUCTIVITY AT TATA ADVANCE SYSTEM LIMITED. NAGPUR

Abstract

This research examines the relationship between the 5S methodology and productivity at Tata Advanced Systems Limited (TASL), Nagpur. The 5S system—Sort, Set in Order, Shine, Standardize, and Sustain—plays a crucial role in lean manufacturing, enhancing workplace organization, efficiency, and safety. The study investigates how the adoption of 5S influences operational performance, reduces waste, and improves overall productivity. A mixed-method research approach was used, combining quantitative data analysis of productivity metrics with qualitative insights from employee surveys and interviews. The results indicate a strong positive correlation between 5S implementation and productivity improvements. Key benefits observed include a reduction in unnecessary movement, lower defect rates, and increased operational efficiency. However, challenges such as sustaining 5S practices, employee resistance, and the need for ongoing training were also identified. The study concludes that successful implementation of 5S leads to measurable productivity gains and recommends regular audits, continuous training, and employee engagement to sustain improvements. These findings contribute to the growing body of research on lean manufacturing practices and highlight the importance of structured workplace organization in enhancing industrial productivity. Future research can explore the long-term financial impact of 5S and its integration with advanced manufacturing technologies.