APPLYING 5S SYSTEM AT ESQUEL GARMENT MANUFACTURING VIETNAM – DONGNAI COMPANY LIMITED

Abstract

In this paper, via a particular case of a garment company, Esquel Ltd. in Dongnai - a southern province of Vietnam, a range of primary and secondary data was collected to assess the effectiveness of 5S implementation. Secondary data gives information about the situation before and after 5S by measuring changes in some key performance indicators (KPIs) over time, whereas primary data from face-to-face interviews gives us commentary assessment of top management and Lean experts about how 5S has changed working conditions of the company. The implementation of 5S to improve working conditions, reduce fabric wastage, increase shipment rates, and reduce operational costs has been evaluated. In addition, PDCA framework accompanied with the 5S method to sustain the daily activities and improve performance continuously is also examined.  The article brings an insight of 5S application for Esquel Ltd. case and summarizes critical factors to successful implementation of 5S. Strengths, weaknesses and learned experiences will be lessons for other businesses to learn and replicate.