Saint Gobain

5S:Our JourneySo-far

5S Excellence Award28th / 29th

September 2007

Is the World Leaderin

Engineered Materials

116th in the Fortune 500 List (2007) :: 1st in its Industry Class

52 Countries

1200 Companies

200,000 employees

5 Business Sectors

Abrasives

Grindwell Norton

Reinforcements

Saint-Gobain Vetrotex India

Saint-Gobain Glass India

Saint-Gobain Sekurit India

Glass

Grindwell NortonSaint-Gobain Crystals & DetectorsSEPR RefractoriesIndia

Ceramics &Plastics

Saint-Gobain Weber India

India Gypsum

Saint-Gobain Seva India

Products

High Performance Materials Flat Construction

Saint-Gobain Businesses in India

177 acres 1300 personnelSingle largest investment destination for Saint Gobain

Saint-Gobain Glass India :World Glass Complex

Brand Building – A Grand Success

Best Practices towardsManufacturingExcellence

Manufacturing Excellence Manufacturing Excellence -- SAFETYSAFETY

First and ForemostFirst and Foremost

Pep Talk/ Tool Box Talk

Hazard Communication Display of LTA Case studies

Hazard Identification Drop Box scheme-Participatory approach for risk reduction

Implementation of Zero Tolerance for Safety Violation

Results :

Manufacturing Excellence Manufacturing Excellence -- SAFETYSAFETY

Mock Drill Mock Drill

Emergency Drill for LPG leakage in Bullet

Combat of Emergency by Fire Fighting Squad

Emergency Medical Management during Mock Drill

Results:

• Average restoration time to regain normalcy : 20 Minutes

• Role of Key Personnel evaluated

• Evacuation was in order

Objective:

To check the emergencyPreparedness and the level of responseacross various levelof the Organization

20052004

20062007

ISO 9001, ISO 14001 For Float Plant

2004

ISO 9001, ISO 14001For SBP & DPP

OHSAS 18001 For Float Plant

CE Marking

OHSAS 18001 For SBP & DPP

ISO 9001, ISO 14001 andOHSAS 18001Extension to Float-II and Coater

Manufacturing Excellence Manufacturing Excellence –– QUALITY SYSTEMSQUALITY SYSTEMS

CertificationsCertifications

Manufacturing Excellence Manufacturing Excellence –– PROCESS EXCELLENCEPROCESS EXCELLENCE

Lean Six Sigma

Launched in May 2007

Series of Training ProgramsExecutive Training

Champions Training

Green Belt Training

Awareness Training

20 Green Belt Projects in Progress

.

Launch : 23rd Jan 2006

280 members and 26 facilitators trained

Monthly QC Review meeting on 1st Saturday of every month.

No of projects completed : 22

No. of teams currently working : 34

Manufacturing Excellence Manufacturing Excellence –– CONTINIUOS IMPROVEMENTCONTINIUOS IMPROVEMENT

Quality CirclesQuality Circles


Quality Circles Competition & RecognitionQuality Circles Competition & Recognition

Jubilant moments of 2 QC teams winning awards from national QC competition in Dec 2006

Jubilant moments of 4 QC teams winning awards from regional QC competition in Sep 2006


Kaizen Competition & RecognitionKaizen Competition & Recognition

Jubilant team in Regional Kaizen competition 2007

MeritoriousCoaterSabiulla M, Santhanam M, Rangaraj N

Cullet bin modification for easy unloading

ExcellentQuality, Float 2Roopkumar D CEBT test for Coater Start up

ExcellentHot end, Float 1Ramachandra RaoTop roll data retrieval from SMQF

OutstandingHot end, Float 2Karthikeyan RLocking Arrangement for the top roll Camera

Award wonDeptNameKaizen topic

• Involvement of people

• Structured method of transforming IDEAS

‘ Suggest Own and Implement’ Concept

Will be inline withMY CONTRIBUTION Scheme of WGM


Suggestion Scheme Suggestion Scheme –– Process FlowProcess FlowEnter in the suggestion form

and drop in the boxes

Make Suggestion in the

SGGI Intranet homepage.

Entered suggestion received by the concerned Sub – Functional Leader.

Sub Functional Leader reviews the feasibility and makes recommendations as:

ACCEPT , HELD or REJECT with suitable comments

Functional Leader takes the decision onACCEPT , HELD or REJECT

The Individual member or CFT implementsthe suggestion and informs the

Sub Functional Leader

Sub Functional Leader verifies and closes the Implemented Suggestion by entering the Benefits ( in My Info)

Individual member can check

the status of his suggestion in

My Info

Summary report of all the Suggestion

can be seen In IMPETUS

Suggestion Review Committee ( SRC) reviews theImplemented suggestions in monthly review meeting

SRC Identifies: Best Implemented SuggestionMax. Implementable Suggestion by an employee

Max. implemented suggestion by a CFT and rewards them

PLANT (SUB) COMMITTEEheaded by Functional Leaders

FL-1: SSRMFL-2: TKCTS-1 : MRTS -2 : NBInt. W/H & Des - RRCoater - KSMirror - SelvaSBP- PRCDPP- PalanisamyIUCS:-Guna

Members: Sub Functional Leaders

SUGGESTION REVIEW COMMITTEE (SRC)RGB ( Convener)MBG (coordinator)SSRM, TKC, RR, NSV, KS, KC, NJL

• Scheme for both SGGI and Outsourced personnel

• Review done by the Suggestion Review Committee

• All Implemented suggestions are being rewarded

• Cross Functional Team that implements the suggestion is also rewarded


Suggestion Scheme : Suggestion Scheme : AwardsAwards

FASTDEEP SKILL TRAINING ON FLOAT PANEL

OPERATION BY GLOBAL TRAINER

FAST TRACK program on Float panel operation to identified members

•Emergency mock drills

•Table top exercises

•Advanced skill training by Global trainer

•Panel evaluation

MKT2

Manufacturing Know How Transfer and Training

• Classroom training using systems

• Field training guided by Mentor

• Step by step approach

• Troubleshooting using incident videos

Manufacturing Excellence Manufacturing Excellence –– PEOPLE & TEAMSPEOPLE & TEAMS

Results :

• Gradual reduction of accidents among contract employees.

• Increased awareness

• Improved shop floor safety discipline.

Objective :

Incorporation of Contractor safety as an integral Part of EHS policy of SGGI

Manufacturing Excellence Manufacturing Excellence –– PEOPLE & TEAMSPEOPLE & TEAMS

Training & PracticeTraining & Practice

Safety Training on LPG operated Mobile Equipments Training on Fire Safety & Emergency Preparedness

Training with Scaled Models on Loading Operation Training on SOP, Material Handling, PPE

5SatSaint-GobainGlass India

Topics:

ObjectivesLaunchOrganization StructureManualPromotional Activities

New PracticesRed Tag System- Online

Mass 5S Activity

5S Walk through Audit

Elite Club

Sustenance activities5S Audits

Rewards / Recognition

Training

Monthly Review

Our 5S OrganizationOur 5S OrganizationChairman

5S Champion

Member Training

Coordinator

Member Standardization

Member Audits

Member Publicizing

Group Leaders

Zone Leaders

Zone Members

Core Team

2525

104104

AllAll

Facilitates Waste Identification and EliminationEnables Visual ControlEnables Standard Operations

Promotes SafetyMakes Perfect Quality possibleBuilds Employee Satisfaction

Objectives of 5SObjectives of 5S

Pre-Launch Promotional Activities

5S Logo and Caption Contest100+ Entries for Logo / Caption

Best Entries Awarded / Adopted

5S Cap‘To Do’ List with 5S Logo

Pre-Launch Promotional Activities

5S Program Launch5S Program Launch

ProgramHighlights

• Logo and Caption Competition

• Zone Identification and Team Formation

• Flag Hoisting & Launch

• 5S Skit • Mass 5S

1212thth June 2006June 2006

5S Chairman unfolding the 5S Flag

5S Program Launch 5S Program Launch –– Mass 5SMass 5S1212thth June 2006June 2006

Before 5S After 5S

It is our Common 5S Language..Common 5S Language..Developed in-house

5S Guidelines, Roles & Responsibilities

Communication / Dissemination Meets

The 5S ManualThe 5S Manual

5S Manual Release & Communication

Saint-Gobain Glass India

Plot-A1, SIPCOT Industrial Park, Sriperumpudur – 602 105

5S Manual

The Information hereon is a property of Saint-Gobain Glass India..

Copying, transmittal to others and any other use except for which it is provided / loaned, is prohibited Query Session

DiscussionDiscussion

Query Session

For Saint Gobain Members

One Day training programme by ABK AOTS.

Compulsory for all new joinees

92 % of members have been covered so far.

For Outsourced Personnel

Conducted by 5S Core team or shift engineers or managers

For 2 hours – relating to their work area

5S Booklet developed in Tamil and Hindi

492 members have been trained so far.

Training done under 2 categories 5S Training5S Training

• Training for both SGGI Employees and outsourced personnel

• Training Material in English and other Local Languages

5S Training5S Training

Sort, Keep only What is Essential for the Work-place

Promotional Activities : Seiri Day : 25th Aug 2006

Before 5S After 5S

Before 5S After 5S

Promotional Activities : Boghi Day : 11th Jan 2007 Before 5S

After 5S

Members involved in SEIRI activities

5S at SGGI : SEITON

BEFORE: Manual Cutting tools are kept on the floor AFTER: A separate structure made for it

BEFORE: Packing materials were kept haphazardly AFTER: 2 bin concept put in to practice and allmaterials were identified

5S at SGGI : SEITON

Temporary marking of movable materials All specifications are displayed

5S at SGGI : SEITON

Place identified for all equipments / materials Place identified for all equipments / materials

5S at SGGI : SEITON

Place identified for all equipments / materials Place identified for all equipments / materials

5S at SGGI : SEITON

Shine

CleaningCleaningWithWith

MeaningMeaning

SeisoSeiso : Shine: Shine

Group 4MuthuSaravananInternal AuditFortnightLong Handled BrushCobwebs Removal - Spout Store8

Group 4MuthuSaravananInternal AuditFortnightWet MoppingFloor Cleaning - Spout Store7

Group 4PrakashInternal AuditFortnightWet ClothRacks Cleaning - Reflectasol Store6

Group 4PrakashInternal AuditFortnightLong Handled BrushCobwebs Removal - Reflectasol Store5

Group 4PrakashInternal Audit FortnightWet MoppingFloor Cleaning - Reflectasol Store4

Group 4MosesInternal AuditFortnightWet ClothRacks Cleaning - Reflectasol3

Group 4MosesInternal AuditWeeklyLong Handled BrushCobwebs Removal - Reflectasol2

Group 4MosesInternal AuditWeeklyWet MoppingFloor Cleaning - Reflectasol1

Done ByResponsibleChecking CriteriaTimeFrequencyTool UsedArea/ItemSl.No

Group 4MuthuSaravananInternal AuditFortnightLong Handled BrushCobwebs Removal - Spout Store8

Group 4MuthuSaravananInternal AuditFortnightWet MoppingFloor Cleaning - Spout Store7

Group 4PrakashInternal AuditFortnightWet ClothRacks Cleaning - Reflectasol Store6

Group 4PrakashInternal AuditFortnightLong Handled BrushCobwebs Removal - Reflectasol Store5

Group 4PrakashInternal Audit FortnightWet MoppingFloor Cleaning - Reflectasol Store4

Group 4MosesInternal AuditFortnightWet ClothRacks Cleaning - Reflectasol3

Group 4MosesInternal AuditWeeklyLong Handled BrushCobwebs Removal - Reflectasol2

Group 4MosesInternal AuditWeeklyWet MoppingFloor Cleaning - Reflectasol1

Done ByResponsibleChecking CriteriaTimeFrequencyTool UsedArea/ItemSl.No

Deep CleaningBefore & After

Cleaning Schedule For Zones / Work-Stations

CleaningCleaningwithwith

MeaningMeaning

Before 5S After 5S

SeisoSeiso: Shine: Shine

Cleaning of the machines and near by areas by the users

Organized Cleaning (Mass 5S) ActivitiesOrganized Cleaning (Mass 5S) Activities

Managing Director to Entry level employee participate

• SOP’s are Displayed at work place

• Flow direction stickers for washing m/c water hoses

• Labels for each hose with colour tags

SeiketsuSeiketsu : Visual Work Place: Visual Work Place

• Emergency Route Escape plan display at various locations.

• PEP TALK circle


• Column footing painted with zebra lines

Pipes running over floor covered with tapered cover plates


* Door range Marking


• Gangway marking



Perpetuate 5S Culture

• Fortnightly Walk-through Observations aiming at driving improvements

• Monthly Audit of all Zones on a 25 Point Scale

• Rolling Trophy for Top Scoring Zone

• Elite Club Status for consistently performing Zones

AuditsAudits

Performance of ZonesPerformance of ZonesAugust 2007August 2007

Audit score displayAudit score display

to review the performanceto communicate all members the future plan of 5S

Zones presenting to management about improvements in 5S at their workplace

5S Monthly Review Meeting

Monthly Review Meeting – 2nd Saturday of every month

To evaluate the understanding of 5S85 % of members took the testTop scored members were rewarded

Promotional Activities : 5S Quiz

Managing Director rewarding the top scored member

5S Industrial Visit

Visit to Model 5S companies4 visits made

Intimate Fashions, ChennaiNippo Batteries, TadaAmararaja Batteries, ThirupathiWendt India, Hosur

Based on observations, actionables implemented.

Visitors to our Plant

10 member team from NIPPO Batteries, Nellore unit visited us on June 2007.8 member team from GMR Energy visited in July 2007

Discussion with the members from NIPPO Batteries

Green & CleanGreen & Clean




IT Enabled

Effective 5S Tracking

IT Support to 5S

Use of IT Systems for effective tracking and reviewing of 5S

Zone DefinitionMonthly 5S audits

Audit feedback

Score sheet

Red Tag System5S Manuals and Formats

5S Home-Page inSaint-Gobain Glass Intranet

Zone Definition

Zone Team Definition

Audit Data entry

Audit Data entry

Audit Scores Display

Audit Feedback

Training Record

Training Record

Red-Tag Creation and Tracking

Red-Tag Creation and Tracking

Red-Tag Register

Recognition

AUAU--TVS : 5S ExcellenceTVS : 5S Excellence4 Star Award 4 Star Award

ABKABK--AOTS AOTS –– 2007 Audit2007 AuditMerit AwardMerit Award

Next Steps

Safety aspects incorporated as 6th S in the monthly 5S Audit

Audit Points – Increased from 25 to 36

Safety Safety –– the the 66thth SS

UK, Korea ….As a first step, M Balaganesh , 5S Coordinator is assisting UK plant in implementing 5S practices.

a month( Aug- Sept,2007 ) stay in UK plant and rolled out 5S Implementation.

Facilitating Sister Plants Facilitating Sister Plants across the Borderacross the Border……

Customers / Vendors …

Most of our processed glass reaches customers through Processors.

Team formed to implement best manufacturing concepts in their workplaces starting from 5S and Quality systemsScheduled from Oct 07.

Stewardship Approach..Stewardship Approach..

Spreading the 5S Culture beyond the WorkplaceSchools…

3 schools selected for implementing 5S.Discussion with School Headmasters and Teachers held in the first week of Sept 07.5S implementation shall be done in phased manner from Oct 07

Beyond the WorkplaceBeyond the Workplace……

Marching Towards Excellence in 5S

Thank You

Documents

Saint Gobain