At a Glance
A client was looking to improve the organization of its maintenance workshop, which was in an accident-prone condition. Together with Unison Mining, it was looking to achieve an improvement of workshop conditions to maintain order, cleanliness and organization. By the end of the project, it successfully achieved this with a standardized, sustainable practice to implement consistently throughout its mine maintenance department.
The Challenge
At the beginning of the project, the client’s maintenance workshop needed more order, cleanliness, and organization. Especially in the workshop yard, where conditions were considered unsafe, it was difficult for anyone to drive without worrying about colliding with a used tire lying around or a hose untangled in the middle of the workshop floor. It was common to find parts, filters, SOS bottles, and trash on the workbenches or to see the satellite storerooms full of old parts, new parts or misplaced manuals, batteries on the floor, or mud near the wash bay.
What We Did
To tackle the disorganization of the client’s workshop, Unison Mining first introduced the 5S methodology. This initiative would be focused not just on cleaning but on ensuring that all parts needed on the floor were accessible, whereas everything that didn’t belong there would be systematically moved to their proper locations.
All parties within the maintenance department took an interest in the initiative and had their respective roles to play. By incorporating the 5S methodology prescribed by Unison, zones in the workshop were assigned specific purposes, and supervisors could better coordinate their roles in keeping the workshop organized. The shop and yard began to grow more organized, removing the need for satellite storerooms and accumulation areas. Instead, these spaces are currently used to prepare for upcoming repairs.
In collaboration with the client’s Maintenance department, we started assigning zones to each work section, including the yard and offices. We provided additional training needed for maintenance teams, developed the strategy, and began performing 5S exercises and designed and implemented audits to ensure compliance and buy-in to these new ways of working. Now, every General Foreman carries out this process daily.
How Unison Mining helped to streamline the client’s spares & tools management:
- Implemented the 5S methodology
- Provided training across all areas within the maintenance department
- Helped in assigning the zones within each work section
- Designed and implemented audit sheets to ensure compliance
- Developed and implemented the process for daily 5S completion reviews
- Implemented the initiative in the client’s satellite maintenance shops and maintenance offices
- Developed the rating system for employee recognition of the 5S adherence
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The Results
- Before implementation of the 5S initiative, the yard was considered a high-risk area because of obstructions due to old tires lying around, garbage cans, and litter everywhere. After implementation, the space is cleaner, more organized and safer to walk and drive in. Maintenance staff ensure that it remains that way by performing their daily 5S audit daily.
- Storage areas are now cleaner and organized, and the space is being used correctly, whereas before older unused parts were mixed with parts needed for repairs. The storage areas are now dedicated to storing only the items needed for upcoming repairs.
- Everyone in the shop and the maintenance offices participates in keeping the work areas clean, organized, and free of unnecessary items that take up aisle space or clog the aisles: no more hoses and cables, dirty worktables, and oil pans.
