Introducing our manufacturing sites.

JOHNAN SIAM applies 5S (Sort, Set in order, Shine, Standardize, Sustain) and continuous improvement (KAIZEN) at its Thai plant to raise quality, reduce defects, improve productivity and ensure a safe workplace. It shares case studies such as QR-based shipping/packing control and system-based material inventory management, and has won the Thailand 5S Award (Bronze, organized by TPA).

With the aim of maintaining not only quality but also a safe environment and productivity at our production sites, we are engaged in 5S activities and other workplace improvement activities on a daily basis. Some of these activities are introduced below.

5S Activities

WHAT IS “5S”?

The generic name for the five words beginning with the S’s of “seiri,” “seiton,” “seiso,” “seiketsu,” and “shitsuke,” these refer primarily to actions that should be taken to improve and maintain the workplace environment in the manufacturing industry.

The Five Pillars of 5S at JOHNAN SIAM:

Seiri (Sort) : Distinguishing between essential and non-essential items, and removing what is unnecessary.

Seiton (Set in Order) : Establishing a designated and efficient place for every item, ensuring quick retrieval and return.

Seisou (Shine) : Maintaining a consistently clean workplace, which aids in easily identifying abnormalities and potential issues.

Seiketsu (Standardize) : Creating a standardized system to ensure that the first three ‘S’s (Seiri, Seiton, and Seisou) are consistently applied and maintained.

Shitsuke (Sustain) : Cultivating the discipline and habit of consistently following established procedures and maintaining the improved workplace standards.

Our 5S activities are rigorously implemented across our entire work site to significantly enhance overall productivity. This is achieved by improving quality and work efficiency, minimizing defective losses, and consistently ensuring a safe and organized work environment.

Below are some illustrative examples of the 5S activities we have successfully implemented.

EXAMPLES OF 5S ACTIVITIES.

Case study: Material Quantity Set-up for Poka-Yoke in the Assembly Process

Problem

  1. Quantity control of materials required for assembly was not properly managed.
  2. The sequence of supplying materials and tools was not standardized, resulting in variation between operators.

Improvements points

  1. Materials were individually set into trays according to the required quantity for each process, reducing the time needed for quantity verification.
  2. The usage sequence of parts and tools was clearly numbered, preventing missed assembly steps and improving work efficiency.

EXAMPLES OF KAIZEN ACTIVITIES.

Case study: Automating Solder Touch-up Process

Problem

  1. Additional soldering in the touch-up process was performed manually, requiring considerable time and labor.
  2. High solder wire consumption and inconsistent soldering quality.

Improvements points

  1. Introduced a selective soldering machine to automate the touch-up process.
  2. Reduced labor and processing time while lowering solder wire consumption, resulting in more stable and improved soldering quality.

Case study：System scan packing control

  1. Duplicative steps: Our procedures include redundant steps that prolong verification.
  2. Time-consuming photo documentation: Recording with photos requires significant time and effort.
  3. Specific manual tasks: These issues are evident in tasks such as:

Problem

Manually verifying the quantity (Qty) before shipment.

Packing Printed Circuit Boards (PCBs) into boxes and re-verifying the quantity.

Taking and saving photos of the quantity along with the delivery tag after verification.

Improvement points

  1. After inspection, the QR code is scanned to verify the quantity in the system.
  2. Based on the packing standard (Packing STD), an automatic check is performed, for example, “300 pieces or 50 sheets per box.”

Case study：System Control Material

Problem

  1. Manual stock card updates: Workers were required to update stock card information by hand.
  2. Inaccurate data: This manual process often led to data inaccuracies due to missed or delayed entries.
  3. Poor inventory accuracy: As a result, our inventory management was unreliable, increasing the risk of stockouts and duplicate material use.
  4. Inefficient tracking: Tracking material status in the warehouse was time-consuming, and reviewing historical data was not efficient.

Improvement points

  1. Automated Stock Card Updates: Now, when raw materials come in, our system automatically updates the stock card information. This eliminates the need for manual entries.
  2. Fewer Manual Errors: This automation has drastically cut down on the errors that used to happen with manual data input.
  3. Real-Time Inventory Visibility: We can now accurately monitor and understand our warehouse inventory in real time.
  4. Boosted Efficiency: As a result, we’ve saved valuable worker time and made our entire inventory management process much more efficient.

Case study：Shelf material WH

Problem

  1. Insufficient storage space: We didn’t have enough room for raw materials.
  2. Time-consuming searches: Operators wasted time looking for materials.
  3. Hindered FIFO: Our First-In, First-Out (FIFO) management was negatively impacted.
  4. SMT material delays: This led to delays in preparing materials for SMT.

Improvement points

  1. Sufficient space secured: We now have ample storage space for raw materials.
  2. Easier material retrieval: Operators can now find materials quickly and easily.
  3. Efficient FIFO & reduced search time: We’ve eliminated wasted time searching for materials, and our First-In, First-Out (FIFO) management is now highly efficient.
  4. Smoother SMT material preparation: The risk of delays in SMT material kitting has been reduced.

Case Study: Optimized Parts Management

Initial Problem

  1. Parts were mixed indiscriminately in storage boxes, leading to difficulties in retrieval and significant time loss.
  2. The absence of First-In, First-Out (FIFO) management created a risk of material deterioration due to prolonged storage.
  3. Improper storage methods directly compromised the quality of the parts.

Improved Solutions

  1. We established designated storage areas and implemented visual management systems for all inventory items, ensuring clear oversight.

  2. To enhance usability and access, different types of equipment are now managed and stored separately.

  3. By arranging parts on dedicated carts, we have successfully implemented a First-In, First-Out (FIFO) system.
  4. Organizing parts by control part number now allows for rapid retrieval of needed components.

Case Study: System control MSL

Initial Problem

  1. MSL floor life is managed and calculated manually.
  2. Calculations are time-consuming.
  3. Recorded data may contain errors or inaccuracies

Improved Solutions

  1. Enhanced data consistency: MSL serial numbers were added to labels and linked with master data, strengthening information integration.

  2. Automated MSL floor life management: MSL floor life management was automated by scanning the MSL serial numbers.

Case Study: Streamlining Production Supply Management

Initial Problem

  1. It was challenging to identify missing production supplies, leading to potential delays.
  2. Disorganized storage resulted in significant time consumption for preparing items for warehouse delivery.

Improved Solutions

  1. We established designated storage areas and implemented visual management for all inventory items, enabling quick identification of supply levels.

  2. To improve efficiency, various types of equipment are now managed and stored separately.

Case Study: Optimizing Workspace & Tool Management

Initial Problem:

  1. Unnecessary items cluttered the work areas.
  2. There was no specified or standardized placement for tools, equipment, and other resources.

Improved Solutions:

  1. We systematically removed unwanted materials, creating a safer and more efficient work environment.

  2. Dedicated storage areas have been established to effectively monitor the usage of tools and equipment.

Case Study: Stationery & Supply Condition Management

Initial Problem:

  1. Stationery and supplies were often left in a damaged condition.
  2. Even unused items were improperly stored or left out.

Improved Solutions:

  1. All equipment is now regularly checked for condition, and any damaged items are promptly discarded.

  2. By implementing fixed location management and promoting shared resource utilization, we have significantly reduced equipment order frequency.

Case Study: Material Warehouse Organization

Initial Problem:

  1. Materials were disorganized, leading to significant time loss in locating specific items.
  2. Missing materials were not readily apparent, impacting production planning.

Improved Solutions:

  1. We have thoroughly organized material placement and implemented clear identification systems for all inventory.

  2. To effectively track and prevent material shortages, our management system now operates on a Max-Min stock level basis.

Recognized Excellence: JOHNAN SIAM Earns Bronze Award at Thailand 5S Award!

Bronze Award Recognition

The Thailand 5S Award is a prestigious convention organized by the Thai-Japan Technology Promotion Association (TPA). Its mission is to promote best practices in 5S activities, elevate industry standards to an international level, and facilitate the sharing of successful 5S implementations among companies and organizations.

We are honored to announce that JOHNAN SIAM participated in the “Thailand 5S Award” for the first time and was proudly awarded the Bronze Award!

This achievement underscores our dedication to operational excellence and continuous improvement.

Award Stages: Our Rigorous Evaluation Process

Stage1.

Document and Examination

Stage2.

Presentation

Stage3.

Initial Factory Audit

Stage4.

Follow-up Factory Audit

Stage5.

Final Presentation

This award provided a valuable platform for JOHNAN SIAM to showcase the impactful results of our rigorous 5S system implementation. We are firmly committed to continuously promoting 5S activities and consistently delivering high-quality services to our valued customers.