Bhubaneswar, Feb 5 (.) The Rourkela Steel Plant (RSP) has recorded notable gains in operational efficiency, workplace safety and cost savings following the successful implementation of the 5S workplace management system at Roll Shop–IV.
The initiative was spearheaded by the ‘Vision’ Quality Circle, marking a significant step towards operational excellence and sustainable manufacturing practices at the plant.
According to RSP sources, Roll Shop–IV plays a vital role in ensuring uninterrupted supply of roll assemblies and shear blades to the New Plate Mill (NPM).
Before the adoption of the 5S system, the shop grappled with issues such as poor housekeeping, cluttered storage areas, inefficient utilisation of space, excessive time spent searching for tools and materials, and potential safety hazards.
To overcome these challenges, the Vision Quality Circle implemented the structured 5S methodology comprising Seiri (Reorganisation), Seiton (Neatness), Seiso (Cleaning), Seiketsu (Standardisation) and Shitsuke (Discipline).
The programme was supported through dedicated committees, extensive employee training and awareness drives, baseline data collection, exposure visits, visual management tools, Red Tag systems, standardised layouts, defined cleaning schedules, periodic audits and Kaizen initiatives.
These concerted efforts resulted in measurable and sustainable improvements across the shop floor. The average search and retrieval time was drastically reduced from five minutes to just 0.5 minutes, while effective space optimisation led to a net saving of 1,080 square metres.
Safety performance also witnessed a marked improvement with the elimination of 18 identified unsafe conditions, significantly reducing potential risks and enhancing overall workplace safety. Better organisation and cleanliness further contributed to improved machine reliability and strengthened preventive maintenance practices.
Additionally, systematic disposal of obsolete and unnecessary materials yielded substantial financial benefits. Through the combined impact of 5S and Kaizen initiatives, Roll Shop–IV achieved total cost savings of Rs. 18,99,425 against a modest implementation cost of Rs. 31,200, reflecting an impressive cost-benefit ratio.

. DP PRS