By applying Lean Kaizen to layout, material presentation and ergonomics, the plant standardised workstations, reduced operator strain and cut non–value-adding movement—improving comfort, safety and productivity without major capital investment.
Context and Challenges
A leading jewellery manufacturer specialising in precision stone processing was facing high ergonomic risk, inconsistent workstation layouts and excessive motion/searching at key stations such as MM girdling, sorting & fixing and bottom polishing. Management wanted to redesign workstations using Lean principles to reduce ergonomic stress, standardise layouts, minimise motion and searching and make the work environment easier to manage and scale.
Our Approach
The improvement was run as a focused Lean Kaizen project on selected jewellery workstations (MM girdling, sorting & fixing, bottom polishing):
- Gemba Study & Ergonomic Assessment: We conducted detailed Gemba observations, mapping micro-motions for key tasks (take parcel, inspect, fix, process, re-check, place in tray). Drew simple movement sketches and applied REBA-based ergonomic assessment to quantify posture risk at each target workstation.
- Workstation Layout & 5S Design: We designed standard 5S layouts for each type of table – defining fixed locations for machines, lenses, lights, tools, infeed/outfeed trays and cleaning items. Introduced clear infeed and outfeed zones so stones and parcels moved in one direction across the table.
- Ergonomics & Reach-Zone Improvement: Implemented height-adjustable chairs with proper support and defined correct seating height/posture guidelines. Reorganised reach zones so frequently used items were within a comfortable arc in front of the operator, and occasional items stored in under-table drawers.
- Material Presentation & Part Storage: Designed a & Implemented compact parts storage rack with small plastic bins on a slanted frame for around 20+ part types, with standard positions and labels. Standardised tray and bin labelling for stone sizes, part types and job/order details to minimise search and mix-ups.
- Standard Work & Capability Building: Documented & Implemented standard work for workstation sequence (infeed → process → inspect → outfeed) aligned to the new layout. Trained operators and supervisors on the new layout, posture guidelines, 5S checks and simple daily audits to sustain improvements.
Key Strategies Implemented
Standardised Workstation Layout & 5S:
- Created visual 5S layouts for key tables, showing standard locations for Machine and lens-on-stand with integrated lighting, Infeed tray, Process area and inspection point, Outfeed tray, Tools, fixtures and cleaning materials.
- Marked and labelled these locations so any operator could set up or reset the station correctly at the start and end of the shift.
Ergonomics & Reach-Zone Optimisation
- Introduced height-adjustable chairs with guidance on how to set seat height and back support for neutral posture.
- Positioned lenses, lights and monitors at appropriate height and distance to reduce neck bending and eye strain.
- Rearranged work surfaces so frequent-use tools and parts were in a small front tray, with occasional-use items moved to side/under-desk storage—reducing stretching and twisting.
Materials & Parts Presentation
- Installed a tilted-bin rack with small, clearly labelled plastic bins for different stone sizes and part types, making items visible and easy to pick/return.
- Standardised bin positions and labels to cut down searching time and avoid using the wrong component.
- Ensured a clear separation between in-process parts, finished parts and tools, with visual cues and boundaries on the workstation.
Standard Work & Daily Discipline
- Defined standard work steps for each workstation, from receiving a parcel to placing finished stones in the outfeed tray.
- Introduced daily 5S and layout checks by operators, supported by simple audit sheets used by supervisors.
- Built basic understanding among operators of how good posture, clean layout and correct reach zones link to quality, speed and fatigue reduction.
Results Achieved
Within a short period of implementing the new layouts and standards, the jewellery plant observed:
- 20% Improvement in manpower productivity at MM girdling, sorting & fixing and bottom polishing stations – REBA scores improved from medium/high to medium/low on targeted workstations.
- 80% reduction in motion and searching waste, as frequent-use items moved into front-of-body trays and parts were stored in clearly labelled, standardised bins.
- Lower operator fatigue and discomfort, especially in back, neck and shoulders, due to better chair height, support and visual arrangements.
- More stable, clutter-free workstations, with visual 5S layouts making it easy to maintain order and quickly spot missing items or abnormalities.