5S Principle

5S is a lean manufacturing methodology to clean and organize the

work place. 5s focuses on having visual order, organization, and
standardization.

SEIRI (SORT OUT)

1.
Do we find items scattered in our
place
2.
Are there boxes paper, cotton waste
and other items left in a disorganized
manner?
3.
All items sorted out and placed in a
designed spots
4.
Are tools and stationary properly
sorted and stored?
SORT OUT ITEMS AND DISCARD THE
UNNECESSARY

SEITION
Are passage ways and storage places
clearly indicated?
Are commonly used and stationary
separated from those seldom used?
Are containers and boxes stacked up
properly?
Are fire extinguisher and hydrants
readily accessible?

 Are there grooves, cranks or bumps on

the floor which hinder the work or
safety?
A PLACE FOR EVERYTHING AND
EVERYTHING IN ITS PLACE

SEISO (CLEANING)
Are the floor surfaces dirty?
Are machines and equipments are
dirty?
Are wires and pipes dirty or stained?
Are machines nozzles directed by
lubricants?
Are shades light bulbs and light
reflectors dirty?

CLEAN YOUR WORK PLACE

THOROUGHLY
SEIKETSU (STANDARDIZING)
Is any ones uniform dirty or untidy?
Are there sufficient light?
Is the noise or heat at your work
place causing leaking?
Is the roof leaking?
Do people eat at designated places
only?

SHITSUKE (TRAINING)
Are regular 5S checks conducted?
Do people clean up without
remainder?
Do people follow rules and
instruction?
Do people wear their uniforms
and safety gear properly?

TRAIN PEOPLE TO BE
DICIPLINED
PULL PRINCIPLE
Customer withdraws the product
from the planned buffer in
production and the withdrawal
triggers the production and there
by regulates the buffer
CUSTOMER SATISFACTION AND
BUSINESS SUCCESS
QUALITY
COST
DELIVERY
Process operation
Pull
principle
Standardization

Mistake operation
Transparency
Waste elimination
Continuous improvement

Flexibility
Responsibility

Brief Introduction to Why Why

Analysis:
The 5 way analysis method is used to
move past symptoms and understand
the true root causes of problems. It is
said that only by asking why? 5 times
successively enough to understand
the ultimate root causes. By the time
you get the fourth or 5th why you will
likely be looking squarely at
management practice. This
methodology is closely related to
cause and effect diagram, and can be
used to compliment analysis
necessary to complete a cause and
effect diagram.

ANALYSIS 1: Frequent wear and

tear of bearing
Why bearings wear out?
Due to Lubrication failure.

 Why lubrication failure in the

bearings?
Due to contamination of
lubricant.
Why lubricant gets
contaminated in bearings?
Due to entering of muck and
coolant particles.
Why muck and coolant
particles entering?
Due to improper sealing
elements.

Fishbone Diagram
Ishikawa diagrams (also called fishbone
diagram, cause-and-effect diagram or
fishikawa) are casual diagrams that show the
causes of a certain event created by Kaoru
Ishikawa(1990). Common uses of Ishikawa
diagram are product design and quality defect
prevention, to identify potential factors causing
an overall effect. Each cause or reason for
imperfection is a source of variation. Causes are
usually grouped into major categories to identify

these sources of variation. The categories

typically include:
Man: Anyone involved with the
process.
Methods: How the process is process
is performed and the specific
requirements for doing it, such as
policies, procedures, rules, regulations
and laws.
Machines: Any equipment,
computers, tools etc. required to
accomplish the job.
Materials: Raw materials, parts, pens,
paper, etc. used to produce the final
product.
Contour monitoring(Problem)