NIOS Class 10 Warehouse Principles & Inventory Management Chapter 13 5S Concept on the Shop Floor Solutions to each chapter is provided in the list so that you can easily browse through different chapters NIOS Class 10 Warehouse Principles & Inventory Management Chapter 13 5S Concept on the Shop Floor and select need one. NIOS Class 10 Warehouse Principles & Inventory Management Chapter 13 5S Concept on the Shop Floor Question Answers Download PDF. NIOS Study Material of Class 10 Warehouse Principles & Inventory Management Notes Paper 259.
NIOS Class 10 Warehouse Principles & Inventory Management Chapter 13 5S Concept on the Shop Floor
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5S Concept on the Shop Floor
Chapter: 13
Intext Questions 13.1
(i) What is the 5S concept?
Ans: 5S is defined as a methodology that results in a workplace that is clean, uncluttered, safe, and well organised to help reduce waste and optimise productivity.
(ii) 5S is often referred to as______________________ in the West.
Ans: Lean Manufacturing.
(iii) ________ is considered as a foundational part of the Toyota Production System.
Ans: 5S.
Intext Questions 13.2
(i) What does 5S stand for?
Ans: Sort, Set in Order, Shine, Standardise and Sustain.
(ii) Match the following.
| (i) Seiri. | (a) Sustain. |
| (ii) Seiton. | (b) Sort. |
| (iii) Seiso. | (c) Standardise. |
| (iv) Seiketsu. | (d) Set in order. |
| (v) Shitsuke. | (e) Shine. |
Ans:
| (i) Seiri. | (b) Sort. |
| (ii) Seiton. | (d) Set in order. |
| (iii) Seiso. | (e) Shine. |
| (iv) Seiketsu. | (c) Standardise. |
| (v) Shitsuke. | (a) Sustain. |
(iii) ____________ stage of 5S focuses on cleaning up the work area.
Ans: Shine.
(iv) The ______________ step involves focusing on what can be done to eliminate risks in work processes by arranging things in certain ways.
Ans: Safety.
(v) When safety is included, the system is often called ___________.
Ans: 6S.
Intext Questions 13.3
(i) List out any two common risks that are found in warehouses.
Ans: Moving machinery and slips, trips and falls.
(ii) What is the reason for slips in any workplace?
(a) Slippery flooring.
(b) Hidden steps and ridges.
(c) Poorly lit areas.
(d) All the above.
Ans: (d) All the above.
(iii) What are the risks that arise during loading and unloading in a warehouse?
Ans: (a) Pinned between forklifts.
(b) Pinned between the loading dock and the truck, trailer or van.
(c) Pinned between vehicles.
(d) Hit by a truck or trailer.
(e) Hit by falling, unsecured items.
(f) Hit by a falling dock plate.
(iv) What causes slips, trips and falls in warehouses?
Ans: (a) Substances littering the floor, such as packaging sawdust and liquids.
(b) Slippery flooring.
(c) Hidden steps and ridges.
(d) Poorly lit areas.
(e) Boxes on the floor.
Intext Questions 13.4
(i) What is meant by PPE?
Ans: Personal protective equipment (PPE) is clothing or equipment designed to be worn by someone to protect them from the risk of injury or illness.
(ii) Mention the safety tips for body protection in the warehouse.
Ans: (a) Ensure that they are clean and free from cuts and burns.
(b) Always get a good fit to ensure full body protection.
(c) Ensure bodysuit is heat-resistant clothing when working with high-temperature hazards.
(iii) Which of the following is not included in PPE?
(a) Face shields.
(b) Uniforms.
(c) Rubber boots.
(d) Gloves.
Ans: (b) Uniforms.
(iv) Identify the statement whether true or false:
Equipment used during competitive sport competitions is considered as Personal Protective Equipment.
Ans: False.
Intext Questions 13.5
(i) Write any three points of the importance of PPE in the warehouse.
Ans: (a) Protects lungs from breathing in contaminated air.
(b) Protects the head and feet from falling material.
(c) Protects the eyes from flying particles or splashes of corrosive liquids.
(ii) What are the factors to be considered, when choosing PPE?
(a) Worker.
(b) Work task.
(c) Work environment.
(d) All the above.
Ans: (d) All the above.
(iii) What is the full form of NIOSH?
Ans: National Institute for Occupational Safety and Health.
(iv) According to the hierarchy of controls by the NIOSH, _____________ is recommended to be the last level of defence to prevent occupational injuries, illnesses, and fatalities.
Ans: PPE.
Intext Questions 13.6
(i) Enlist any four uses of PPE.
Ans: (a) Head protection.
(b) Hand protection.
(c) Eye protection.
(d) Foot protection.
(ii) Which of the following is must in warehouses with little light or in facilities in which operators frequently cross paths with handling equipment?
(a) Helmet.
(b) Footwear.
(c) High visibility clothing.
(d) Earplugs.
Ans: (c) High visibility clothing.
(iii) ______________ provide effective protection in the event of a falling object.
Ans: Helmet.
(iv) ______________ is aimed at protecting the most delicate parts of the body.
Ans: PPE.
| Terminal Exercise |
1. What is the 5S system in a warehouse?
Ans: 5S is defined as a methodology that results in a workplace that is clean, uncluttered, safe, and well organised to help reduce waste and optimise productivity. It is a system for organising spaces so that work can be performed efficiently, effectively, and safely. This system focuses on putting everything where it belongs and keeping the workplace clean, which makes it easier for people to do their jobs without wasting time or risking injury. 5S began as part of the Toyota Production System (TPS), the manufacturing method begun by leaders at the Toyota Motor Company in the early and mid-20th century.
2. What are the parts of 5S?
Ans: The parts of 5S are discussed below:
(i) Sort: The first step of 5S, Sort, involves going through all the tools, furniture, materials, equipment, etc., in a work area to determine what needs to be present and what can be removed.
Some questions to ask during this phase include:
(a) What is the purpose of this item?
(b) When was this item last used?
(ii) Set in Order: Once the extra clutter is gone, it’s easier to see what’s what. Now work groups can come up with their own strategies for sorting through the remaining items.
Things to consider:
(a) Which people (or workstations) use which items?
(b) When are items used?
(c) Which items are used most frequently?
(iii) Shine: The Shine stage of 5S focuses on cleaning up the work area, which means sweeping, mopping, dusting, wiping down surfaces, putting tools and materials away, etc. In addition to basic cleaning, Shine also involves performing regular maintenance on equipment and machinery, planning for maintenance ahead of time means businesses can catch problems and prevent breakdowns. That means less wasted time and no loss of profits related to work stoppages.
(iv) Standardise: Once the first three steps of 5S are completed, things should look pretty good. All the extra stuff is gone, everything is organised, spaces are cleaned, and equipment is in good working order.
The problem is, when 5S is new at a company, it’s easy to clean and get organised and then slowly let things slide back to the way they were. Standardise makes 5S different from the typical spring-cleaning project.
(v) Sustain: Once standard procedures for 5S are in place, businesses must perform the ongoing work of maintaining those procedures and updating them necessary, Sustain refers to the process of keeping 5S running smoothly, but also of keeping everyone in the organisation involved. Managers need to participate, as do employees out on the manufacturing floor, in the warehouse, or in the office. Sustain is about making 5S a long-term program, not just an event or short-term project. Ideally, 5S becomes a part of an organisation’s culture.
3. What is meant by PPE?
Ans: Personal protective equipment (PPE) is clothing or equipment designed to be worn by someone to protect them from the risk of injury or illness. The hazards addressed by protective equipment include physical, electrical, heat, chemicals, biohazards, and airborne particulate matter.
4. Write about the 6th S in 6S system?
Ans: Some companies like to include a sixth 5 in their 5S program: Safety. When safety is included, the system is often called 6S. The Safety step involves focusing on what can be done to eliminate risks in work processes by arranging things in certain ways. This might involve setting up workstations so they’re more ergonomic, marking intersections such as the places where forklifts and pedestrians cross paths-with signs, and labelling the storage cabinet for cleaning chemicals so people are aware of potential hazards. If the layout of the workplace or the tasks people perform are dangerous, those dangers should be reduced as much as possible. That’s what the sixth S focuses on.
5. How to reduce risk from falling objects?
Ans: Make sure your team knows how to stack loads (especially heavy ones) as neatly and securely as possible so that they do not shift and fall. If objects are cylindrical or irregular in shape, ensure they are stacked in a safe way.
6. What is the importance of the 5S system?
Ans: 5S is designed to decrease waste while optimising productivity through maintaining an orderly workplace and using visual cues to attain more consistent operational results. 5S refers to five steps – sort, set in order, shine, standardise and sustain.
7. How to reduce the risk from exposure to harmful substances?
Ans: Ensure that your team is trained on safety procedures and consistently stick to them. Growing complacent or careless over time can lead to accidents and severe injuries that could have easily been prevented by following the proper procedures. For instance, only team members who have been trained to handle harmful substances should do so. Your team should also be wearing the appropriate personal protective equipment (PPE) when handling harmful substances.
8. State the risks that are resulted from loading and unloading?
Ans: Warehouse workers are often required to load and unload items.
This can possibly lead to being:
(i) Pinned between forklifts.
(ii) Pinned between the loading dock and the truck, trailer or van.
(iii) Pinned between vehicles.
(iv) Hit by a truck or trailer.
(v) Hit by falling, unsecured items.
(vi) Hit by a falling dock plate.
9. What are the reasons for slips, trips and falls in warehouses?
Ans: This hazard is one of the most common causes for accidents in any workplace.
In a warehouse, they can be caused by:
(i) Substances littering the floor, such as packaging sawdust and liquids.
(ii) Slippery flooring.
(iii) Hidden steps and ridges.
(iv) Poorly lit areas.
(v) Boxes on the floor.
10. What are the things that are included in PPE?
Ans: The things that are included in PPE are:
(i) Hearing protective devices, such as ear muffs and ear plugs.
(ii) Respiratory protective equipment and face protection, such as safety glasses and face shields.
(iii) Safety helmets.
(iv) Fall arrest harnesses for working at heights.
(v) Skin protection, such as gloves, gauntlets and sunscreen.
(vi) Clothing, such as high visibility vests, life jackets and coveralls.
(vii) Footwear, such as safety boots and rubber boots.
11. Explain about the five terms of the 5S concept?
Ans: The term 5S comes from five Japanese words:
(a) Seiri.
(b) Seiton.
(c) Seiso.
(d) Seiketsu.
(e) Shitsuke.
In English, these words are often translated to:
(i) Sort: The first step of 5S, Sort, involves going through all the tools, furniture, materials, equipment, etc., in a work area to determine what needs to be present and what can be removed.
Some questions to ask during this phase include:
(a) What is the purpose of this item?
(b) When was this item last used?
(ii) Set in Order: Once the extra clutter is gone, it’s easier to see what’s what. Now work groups can come up with their own strategies for sorting through the remaining items.
Things to consider:
(a) Which people (or workstations) use which items?
(b) When are items used?
(c) Which items are used most frequently?
(iii) Shine: The Shine stage of 5S focuses on cleaning up the work area, which means sweeping, mopping, dusting, wiping down surfaces, putting tools and materials away, etc. In addition to basic cleaning, Shine also involves performing regular maintenance on equipment and machinery, planning for maintenance ahead of time means businesses can catch problems and prevent breakdowns. That means less wasted time and no loss of profits related to work stoppages.
(iv) Standardise: Once the first three steps of 5S are completed, things should look pretty good. All the extra stuff is gone, everything is organised, spaces are cleaned, and equipment is in good working order.
(v) Sustain: Once standard procedures for 5S are in place, businesses must perform the ongoing work of maintaining those procedures and updating them necessary, Sustain refers to the process of keeping 5S running smoothly, but also of keeping everyone in the organisation involved. Managers need to participate, as do employees out on the manufacturing floor, in the warehouse, or in the office. Sustain is about making 5S a long-term program, not just an event or short-term project. Ideally, 5S becomes a part of an organisation’s culture.
12. Explain the common risks that are found in warehouses.
Ans: The common risks that are found in warehouses are:
(i) Physical Strain: Warehouse workers often have to handle heavy, bulky items and over time, this can lead to varying levels of physical strain. However, physical strain can be hard to identify because every worker’s body is different. You cannot predict how long a person will be able to withstand prolonged exposure to physical labour.
(ii) Moving Machinery: Warehouse machinery has the potential to be extremely dangerous if your team is not using it properly. Many machines have moving parts that can potentially cause serious injuries if safety precautions aren’t followed.
(iii) Loading and Unloading: Warehouse workers are often required to load and unload items.
This can possibly lead to being:
(a) Pinned between forklifts.
(b) Pinned between the loading dock and the truck, trailer or van.
(c) Pinned between vehicles.
(d) Hit by a truck or trailer.
(e) Hit by falling, unsecured items.
(f) Hit by a falling dock plate.
(iv) Falling Objects: Items can easily fall down and injure your team. In addition, items might be stacked high when your workers are moving them from place to place. Again, they can easily slip off and cause potential injuries.
(v) Exposure to Harmful Substances: Toxic substances are a serious workplace hazard. Even cleaning products can potentially injure your team if they are not wearing the appropriate gear or handling the substances properly.
(vi) Lack of Safety Training and Knowledge: As you might have noticed while reading this article, training your team on the appropriate safety measures is one of the main ways to reduce the risk of hazards. That’s why insufficient safety training is a big hazard in itself. If your team is not working in a safe manner, they are making it more likely for any of the other hazards to cause an accident.
(vii) Slips, Trips and Falls: This hazard is one of the most common causes for accidents in any workplace.
In a warehouse, they can be caused by:
(a) Substances littering the floor, such as packaging sawdust and liquids.
(b) Slippery flooring.
(c) Hidden steps and ridges.
(d) Poorly lit areas.
(e) Boxes on the floor.
13. Write about the importance of PPE in the warehouse.
Ans: Here are some benefits of using PPEs:
(i) Prevent unnecessary injury in the workplace.
(ii) Protect employees from excessive chemical exposure.
(iii) Prevent the spread of germs and infectious diseases including COVID-19.
(iv) Help businesses comply with regulatory requirements(e.g., The Personal Protective Equipment at Work Regulations 1992 that’s recently been extended to limb workers).
(v) Improve employee productivity and efficiency.
14. Explain about the factors to be considered, while choosing PPE.
Ans: The factors to be considered while choosing PPE are:
(i) Worker: Check the PPE is a suitable size and fit for each worker. Respiratory protective equipment, for example, requires a good facial seal. If PPE is comfortable to wear and workers are involved in choosing it, they will be more likely to use it.
(ii) Work task: Match the PPE to the hazard, remembering that a work task may expose workers to more than one hazard. For example, welders may need protection from harmful welding gases and fumes, as well as ultraviolet radiation, hot metal and sparks.
(iii) Work environment: Understand the impacts of a hot and humid work environment. If you are protecting against exposure to a substance such as a hazardous chemical or a biological substance. Consider how the substance can enter the body. For example, where a chemical can be absorbed through the lungs and skin, skin protection as well as respiratory protection may be required.
(iv) Do not reuse single-use PPE, for example, disposable gloves. Maintenance, Proper care and maintenance is essential to ensure PPE continues to provide the necessary level of protection.
(a) Look for broken or damaged components before using PPE and repair or replace it as needed.
(b) Replace PPE that has expired or reached its usable lifespan.
(c) Clean reusable PPE after use and store in a clean area such as a cupboard, drawer on resealable container.
(d) Report broken, damaged or contaminated PPE.
15. What are the uses of PPE?
Ans: The following are the various uses of PPE:
(i) Head protection: Helmets provide effective protection in the event of a falling object. The various types of helmets and models (with a long, medium, or short visor, without a visor, etc, are designed to cushion impacts and resist puncture and flames.
(b) Hand protection: It is important to pay special attention to hand care, as fingers can be easily injured. Although moving boxes and pallets seems simple, they can actually produce deep cuts.
(iii) Eye protection: This is tasked with protecting the eyes of the operator from any foreign body that could enter into contact with the eyeball, mainly splashes of chemicals, dust particles in the air, liquid aerosols, and UV radiation.
(iv) Foot protection: The use of suitable footwear is essential. It not only protects operators from falling objects, blows to the instep and heel, and when stepping on sharp or pointed objects; it also helps to reduce the feeling of fatigue and ward off illnesses associated with standing all day long.
(e) Hearing protection: Working in a noisy environment can lead to loss of hearing, although it can also have other less evident effects on a person’s health. Warehouses are facilities that produce a lot of noise, so operators need to protect themselves with earmuffs, earplugs, or helmets with ear muffs that lessen the noise level.
(f) High-visibility clothing: Protective clothing covers or is worn in place of personal clothing. Hi-vis clothing is a must in warehouses with little light or in facilities in which operators frequently cross paths with handling equipment.
