5S Method

5S is a simple and effective way to eliminate industrial waste.

Create a safe, organized and productive work area with these 5 steps:

SUSTAIN SORT

STANDARDIZE
SET IN ORDER

SHINE
 7QC TOOLS

CHECK SHEET
FISHBONE DIAGRAM

PARETO CHART

SCATTER DIAGRAM
CONTROL CHART

HISTOGRAM
FLOW CHART
 SMED
It is a manufacturing methodology that aims to reduce the time it takes to change a die in a manufacturing process.

The goal of SMED is to reduce the changeover time to less than 10 minutes.

Identify and separate:

Select the process record Convert Internal to
Internal and External
time for changeover External activities
activities

Optimize internal and Make adjustments and

external activities do changeover
POKA-YOKE (Mistake Proofing)
Poka-Yoke is a system of preventing mistakes or defects in manufacturing processes.

It can be used to prevent a wide variety of mistakes including below:

 Using the wrong parts

 Incorrect assembly Describe

 Wrong measurements
Before After
Implement Locate
 Damaged products
Mobile Charging socket

Root cause Analyze

PLUG SOCKET
 PDCA CYCLE
What is PDCA cycle?

PDCA stands for Plan-Do-Check-Act cycle.

PDCA is one of the popular continuous improvement Methodologies.
1 2
4 Phases of PDCA Cycle
 Plan – A change aimed at Improvement
 Do – Carry out the change Identify the problem discover
 Check – Study the results where and why it started
Involve EVERYONE and
 Act – Adopt, adapt or abandon Plan the improvements PLAN DO EXECUTE the plan
create a plan of action

Benefits of PDCA Approach:

 Standardization RESTART cycle
 Data-driven decisions
 Continuous Improvements REFLECT what can be
changed ACT CHECK ANALYZE to see if everyone
went as planned and if the
 Improved problem solving expected result occurred
SHARE the learning
 Teamwork and collaboration
STANDARDIZE the process

4 3
 kaizen
It is a philosophy of continuous improvement that can be applied to all aspects of life, including manufacturing,
business, and personal life.

The goal is to make small, incremental improvements on a regular basis which leads to significant improvements
over time

What is KAIZEN ? SIX Steps of KAIZEN

Kaizen comes from the 1 IDENTIFY PROBLEM

Japanese words “KAI” which
means change or improvement 2 ANALYZE PROBLEM
& “ZEN” which means
For betterment. 3 DEVELOP AN OPTIMAL SOLUTION
4 IMPLEMENT SOLUTION
KAIZEN is very famous Lean
tool for manufacturing. 5 STUDY AND ANALYZE THE RESULTS

6 STANDARDIZE THE SOLUTION

8 Lean Manufacturing wastes
What is waste in Lean Manufacturing ?
T-TRANSPORTATION
 In simple language, It is something that adds no value.
 Our customer would not be happy to pay for any actions that we take is called wastes.
 People usually think about all of the scrap material that gets thrown away. They often forget about I-INVENTORY
all of the other actions that wastes our time, resources and money.

M-MOTION

W-WAITING
Benefits of elimination of lean wastes O-OVERPRODUCTION
 It improves efficiency and effectiveness.
 Increase the productivity of the production process.
 It will increase the performance of plant indicator OEE. O-OVERPROCESSING
 It creates a safer working environment for all employees.
 Reduces DOWNTIME.
D-DEFECTS

S-SKILLS SETS
 ISHIKAWA DIAGRAM
It is a visual tool that can be used to identify the root causes of a problem.

The main problem statement is then broken down into smaller problems, which are written on the "bones" of the fish.
These smaller problems can then be broken down further into even smaller problems

MANPOWER METHOD MACHINE

MATERIAL MOTHER
NATURE MEASUREMENT
 RCA: ROOT CAUSE ANALYSIS
Root cause analysis (RCA) is a process of identifying the underlying factors that contributed to an event or problem.

By identifying and eliminating the root causes of problems, RCA can help to improve quality, reduce costs, improve safety,
and increase customer satisfaction.

Determine possible Identify the root Recommend and

Realize the problem Gather data
casual factors cause implement solution
 GEMBA
What is GEMBA?

Gemba refers to the actual place where work is performed. This can be the factory floor, the warehouse, or any other
location where value is created.

Gemba walks is to understand the actual state of the workplace. This is done by observing the work being done, talking
to the people who are working, & asking questions.

COOPERATE
SOLVE
OBSERVE PROBLEM

COMMUNICATE RACOGNISE
What is 8D method? 8D: Method
The 8D Method, or Eight Disciplines Problem Solving, is a structured approach used to address and solve complex
problems, often in manufacturing and quality control contexts. It helps teams identify, analyze, and rectify issues while
also preventing recurrence.

1D ESTABLISH THE TEAM

DESCRIBE THE PROBLEM 2D

DEVELOP INTERIM CONTAINMENT

3D
ACTIONS

DEFINE & VERIFY ROOT CAUSE &

4D
ESCAPE POINTS

CHOOSE & VERIFY PERMANENT

5D
CORRECTIVE ACTIONS

IMPLEMENT & VELIDATE

6D
PERMANENT CORRECTIVE ACTIONS

SYSTEM PREVENTION ACTIONS TO

7D
PREVENT A RECURRENCE

RECOGNIZE TEAM CONTRIBUTIONS 8D