Journal of Tea Science Research. 2015, Vol. 5, No. 6, 1-14
1
Research Report Open Access
Effectiveness of 5S Application in Tea Industry and Synchronization of 5S
into ISO 22000:2005
Lokunarangodage C.V.K.
, Wickramasinghe I., Ranaweera K.K.D.S.
Department of Food Science and Technology, Faculty of Applied Sciences, University of Sri Jayewardenepura, Gangodawila, Nugegoda, Sri Lanka
Corresponding author email
Journal of Tea Science Research, 2015, Vol.5, No.6 doi: 10.5376/jtsr.2015.05.0006
Received: 30 Sep., 2015
Accepted: 18 Oct., 2015
Published: 20 Nov., 2015
© 2015 Lokunarangodage et al., This is an open access article published under the terms of the Creative Commons Attribution License, which permits
unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Preferred citation for this article:
Lokunarangodage C.V.K., Wickramasinghe I. and Ranaweera K.K.D.S., 2015, Effectiveness of 5S Application in Tea Industry and Synchronization of 5S into
ISO 22000:2005,
Journal of Tea Science Research, 5(6), 1-14
(doi
Abstract
A study was conducted to develop an ISO 22000 generic model for tea industry in synchronization with 5S while
considering changes in currently adapted systems, processes, practices and adaptation to design synergetic technical solutions. Thus
all stakeholders in tea manufacturing process were interviewed and requested to use the developed documents as a user innovation
strategy and incorporated progressive changes in design until both document management and user’s requirements were satisfied.
The documents were prepared in local language and 5S work instructions were enriched with food hygiene requirements instead of
developing new set of instructions where harmonization, modification and adaptation was very effective. Work instructions, cleaning
and housekeeping were further integrated while enriching with relevant standards to be met after cleaning as well as relevant records
and references. Consequently, work instructions, preventive maintenance, general housekeeping, training and standardization were
properly synchronized where it was used from existing 5S systems with modifications to harmonize and comply with ISO 22000 as
well as 5S requirements which reduced the time spent for recordings on two systems. Synchronization reduced the number of
documents used in the food safety management system up to a great extent and frequency of recording while improving the
effectiveness of recording.
Keywords
ISO 22000; 5S; Synchronization; Work Instructions; Tea Manufacturing; Orthodox Black Tea
Introduction
As a medicinal crop tea has been grown in China
over five thousand years, to become a USD 4 billion
industry today (Fair-trade foundation, 2010) which
has employed more than 15 million people around
the world to serve over four billion tea cups a day.
The scotch man James Taylor was became the first
commercial tea planter in Sri Lanka, who planted
approximately 8 ha of tea on Loolecondera at
Hewaheta in Kandy district in 1867, which is still in
production (Fuches, 1989; Boyle, 2012).
Sri Lanka is one of the oldest tea producing
countries in the world. Commercial tea plantation
and production in Sri Lanka commenced almost 148
years. Sri Lankan tea was branded and known as
Ceylon Tea which is ranked one of the superior teas
among the teas available in the international trade
and over the years the word Ceylon has become
synonymous with quality tea (Mohamed and Zoysa,
2006). The major product of the country is orthodox
black tea which accounts for 95% of the total
production with the balance being cut, tear and curl
(CTC) that was mainly utilized for tea bags. The
instant tea and green tea productions were very
minimal compared to the orthodox black tea
manufactured in the country (Mohamed and Zoysa,
2008).
Sri Lankan tea industry annually produced around
320 million kilograms of made tea according to the
current statistics available. Out of the given production
output, country has manufactured approximately
95% orthodox black tea annually which basically
intended for export representing 32% of the global
demand on orthodox black tea (Ministry of
Plantation Industries, 2013). The CTC and green tea
represents only 5% of the total production and
country manufacture tea throughout the year. The
growing areas were distributed differently and
