5's principles & 8'd methods

5S PRINCIPLES

THE SECRET TO

JAPANESE SUCCESS

U.KALPANADEVI

II- MBA

MICHAEL INSTITUTE OF MANAGEMENT

• Developed by the Japanese• Housekeeping System• Helps Create a Better Working Environment

and a Consistently High Quality Process

DE

LIV

ER

Y

SE

RV

ICE

IF WE CANNOT KEEP OUR WORKPLACES

CLEAN

ORDERLY

ACCIDENT FREE

NOBODY WILL BELIEVE WE CAN PRODUCE QUALITY GOODS OR ATLEAST SERIOUS ABOUT PRODUCING QUALITY.

• SEIRI – Organisation/Sort out

• SEITON – Orderliness/Systemize

• SEISO – The Cleaning/Shining

• SEIKETSU – STANDARDIZE

• SHITSUKE - Sustain/Discipline

Sort Means That You RemoveAll Items From the WorkplaceThat Are Not Needed for CurrentProduction Operation.

A WORK ENVIRONMENT IN WHICH TIME

MONEY

SPACE

ENERGY &

EFFECTIVE RESOURCES MANAGMENT

PROBLEMS IN WORK FLOW ARE REDUCED,

COMMUNICATION IS IMPROVED, PRODUCT

QUALITY IS INCREASED & PRODUCTIVITY IS

ENHANCED.

WASTE

ELIMINATION

LEADS TO

COST

OPTIMIZATION &

MANAGEMENT

EXCELLENCE

Set in Order Can Be Defined As Arranging Needed Items So That They Are Easy to Use and Labelling Them So That They Are Easy to Find and Put away.

WASTE OF

MOTION

SEARCHING

HUMAN ENERGY

EXCESS INVENTORY

DEFECTIVE PRODUCTS

UNSAFE CONDITIONS

DECIDING APPROPRIATE LOCATIONS

LOCATE ITEMS IN THE WORKPLACE

ACCORDING TO THEIR FREQUENCY OF USE

PLACE FREQUENTLY USED ITEMS NEAR THE

WORKPLACE

STORE INFREQUENTLY USED ITEMS AWAY

FROM THE PLACE OF USE.

A LET GO ARRANGEMENT FOR TOOLS SO

THAT THEY GO BACK TO ORIGINAL PLACE OF

STORAGE

Shine Means Sweeping

Floors, Whipping off

Machinery, and Generally

Making Sure That Everything

in the Factory Stays Clean.

This step eliminates Dirt, Dust and other

foreign matter to make the workplace clean.

Clean Equipment,Furniture,Notice Boards

Records Etc.

Keep the workplace Spotless.

Sweeping,wiping,polishing,painting Etc.

Standardize Is The Result That Exists When the First Three Pillars - Sort, Set in Order and Shine Are Properly Maintained.

Set in Order

Machinery

Where

Things

Are Kept

OPERATION

Critical

Processes

Communication

Inventory

STANDARDIZATION

PROVIDE OBJECTIVES AND INDICATE

TRAINING GOALS.

PROVIDE A BASIS FOR TRAINING

CREATE BASIS FOR AUDIT AND

DIAGNOSIS.

PROVIDE A MEANS FOR PREVENTING

RECURRENCE OF ERRORS AND

MINIMIZING VARIABILITY.

Sustain means making a habit of properly maintaining correct procedures.

THIS STEP IS TO ENSURE THAT EVERYONE

STICKS TO THE RULES SCRUPULOUSLY

AND MAKES IT A HABIT

CREATE GENERAL AWARENESS ABOUT

4S.

TRAINING TO EVERYONE.

DEVELOP NORMS AND MONITOR

SUCCESS.

High employee Morale.

Involvement of People in the Movement.

Let us create our own work place with our own hands. Let us contribute to a cleaner work place.

6th. S is now included as “SHIKKARI YAROU” -- “let us try hard”.

Every person should show initiative and make a special effort.

8 DISCIPLINES OF PROBLEM SOLVING

HISTORY

was created by U.S Department Of Defence

(DOD) in 1974.

Standard was officially abolished in 1995, but

the 8D methodology has been propagated by

ford in the Automotive industry and is well

known to many companies in the electronics

industry.

PURPOSE

To identify , correct & eliminate recurring

problems.

It is useful in product and process

improvement.

It follows the logic of PDCA cycle.

8 DISCIPLINES:

D0: PLAN

D1: USE A TEAM

D2: DEFINE & DESCRIBE THE PROBLEM

D3: DEVELOP INTERIM CONTAINMENT PLAN; IMPLEMENT &

VERIFY INTERIM ACTIONS

D4: DETERMINE, IDENTIFY AND VERIFY ROOT CAUSES &

ESCAPE POINTS

D5: CHOOSE & VERIFY PERMANENT CORRECTIONS(PCs)

FOR PROBLEM/ NON – CONFORMITY

D6: IMPLEMENT AND VALIDATE CORRECTIVE ACTIONS

D7: TAKE PREVENTIVE MEASURES

D8: CONGRATULATE YOUR TEAM

D0: PLAN Plan for solving the

problem & determine the pre requisities.

D1: USE A TEAM

Establish a team of

people with product /

process knowledge.

D2: DEFINE & DESCRIBE THE PROBLEM:Specify the problem by identifying

quantifiable terms for the problem.

D3: DEVELOP INTERIM CONTAINMENT PLAN;

IMPLEMENT & VERIFY INTERIM ACTIONS:

Define & implement containment actions to isolate the problem from any customer

D4: DETERMINE, IDENTIFY AND VERIFY ROOT CAUSES &

ESCAPE POINTS:

Identify the problems thst explain the

problem

D5: CHOOSE & VERIFY PERMANENT

CORRECTIONS(PCs) FOR PROBLEM/ NON

– CONFORMITY:

Through pre production programs

quantitatively confirm the correction

D6:IMPLEMENT AND VALIDATE

CORRECTIVE ACTIONS:

Define & implement the best

corrective actions

D7: TAKE PREVENTIVE MEASURES:

Modify the management systems,

operation systems, practices 7 procedures to

prevent the recurrance of similar problems.

D8: CONGRATULATE YOUR

TEAM: Recognise the

collective efforts of the team .

The team needs to be formally

thanked by the organisation.