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    5

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    5S HOUSE KEEPING

    5S is a practice of housekeeping used to establish andmaintain a productie and !ualit" enironment

    #ell organi$ed %orkplace & safer' e(cient ) more prodenironment

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    O*+E,-I.ES O/ 5S

    -o create a clean ) neat %orking place

    -o s"stemati$e da" to da" %ork

    -o improe %ork e(cienc"

    -o standardi$e %ork practices

    -o improe %ork discipline-o improe !ualit" of %ork ) products

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    /0,-O1S IN I2P3E2EN-I5S

    4 Participation b" all

    6 -op management commitment

    7 Should be self sustaining

    8 1eie% the program

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    *ENE/I-S9

    Simpli:cation of process

    Increases material isibilit"

    1e energi$es %ork force

    Improes !ualit" management

    ,lean ) safe %ork enironment Increases e(cienc" of operations

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    ;IS0;.0N-0GES

    -ime consuming

    Inappropriate starting point

    3oss of e

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    =U03I-> ,I1,3

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    IN-1O;U,-ION

    =, is a oluntar" group

    ?@4A people from arious departments

    2eet eer" fortnight or periodicall"

    3ead b" =ualit" 3eader ) members are called =, 2em

    Once formed sets their o%n reference' standards' term No eBtra compensation %ill be gien

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    ,H010,-E1IS-I,S O/ =

    .oluntar" membership

    -raining

    Problem soling

    Group process

    ,ontinuous process 2anagement support

    1ecognition

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    ;E.E3OPING =,

    Start up phase

    ,onstitution of =,

    Initial problem soling

    Presentation ) approal of suggestions

    Implementation

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    -E,HNI=UES USE; /O;IS,USSION IN =,

    *rain@Storming

    ,ause ) E

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    0;.0N-0GES9

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    2E-HO;O3O

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    IN-1O;U,-ION

    Problem soling method for product ) process improe

    Eight disciplines & emphasi$ing team s"nerg"

    E

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    O*+E,-I.ESD

    Structured problem soling ) correctie action

    Understand importance of :nding root cause

    Understand %aste ) process control

    Use of statistical tools for problem soling

    ;eelop action plans to perform problem soling

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    C ; ;IS,IP3INESF

    4 ; 4 & Establish the team

    6 ; 6 & ;escribe the problem

    7 ; 7 & ;eelop interim containment actions

    8 ; 8 & ;e:ne ) erif" root cause ) escape points

    5 ; 5 & ,hoose ) erif" permanent correctie action

    ? ; ? & Implement permanent correctie action

    ; & Preent recurrence

    C ; C & 1ecogni$e team ) indiidual contribution

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    *ENE/I-S

    Useful in product ) process improement

    E

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    3I2I-0-IONS

    -ime ) e

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    -0GU,H,ON-1I*U-I

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    IN-1O;U,-ION

    Engineer ) Statistician

    2ade a lot of contribution to industrial statistics

    0docated that the design of the product should be robenough such that it doesnt get a

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    ,ON-1I*U-IONS

    4 =ualit" 3oss /unction =3/F

    6 Orthogonal 0rra"s

    7 =ualit" Engineering

    8 Signal to Noise 1atio

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    4 =U03I-> 3OSS /UN,-I

    Statistical methods deeloped b" Genichi -aguchi

    0ims to improe !ualit" of manufactured goods

    ,ontradictor" to man" %estern methods

    ,ontributions includeD

    4 -aguchi loss function6 Philosoph" of o

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    -0GU,HI 3OSS /UN,-IO

    -aguchi de:nes !ualit" as the loss impaired b" the prosociet" from the time product is shippedJ

    3oss includes cost to operate' failure to function' maint) repair costs' customer dissatisfaction' inuries causedpoor design ) similar costs

    ;efectie parts before shipment are not considered as this loss

    #heneer a product deiates from its target performangenerates a loss to societ"

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    -0GU,HI .S -10;I-ION0PP1O0,H

    ,onsider t%o products

    One %ithin speci:ed limit ) other outside limit

    -raditional approach & one %ithin limit is good ) outsidbad

    -aguchi & %hen a product moes out from its limit it ca

    losses

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    -0GU,HIS =U0;10-I,=U03I-> 3OSS /UN,-IO

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    =3/

    3BF L kB@NFM6

    3BF & loss function

    k & constant of proportionalit"

    B & !ualit" characteristic of selected product

    N & Nominal alue of chosen product B & NF @ tolerance

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    6 =U03I-> ENGINEE1IN

    Uses designed eBperiments to improe product ) proce!ualit"

    Engineers hae to achiee ideal product function

    Products & designed to reduce losses

    -hree stagesD

    0 S"stems design

    * Parameter design

    , -olerance design

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    0 S>S-E2S ;ESIGN

    ,onceptual design stage

    Scienti:c ) Engineering eBpertise is applied

    Under normal conditions' original ) ne% technolog" s"are deeloped

    3ess focus compared to other stages

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    * P0102E-E1 ;ESIGN

    1obust design & cornerstone of -aguchis philosoph"

    -hree product deelopment stagesD

    4 Product design

    6 Process design

    7 Production.Onl" at product design counter measures are possible aall sources of ariations

    .Parameter design & selection of optimum conditions so tproduct is least sensitie to ariations

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    , -O3E10N,E ;ESIGN

    -olerance studies & to determine the ariables %hich hacritical tolerances that need to be tightened

    S"stematic procedure of identif"ing crucial noise factorsuggests the most cost e

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    7 SIGN03 -O NOISE 10-

    Statistical performance measure tool deeloped b" -ag Simpl" the ratio of mean signalF to the standard deianoiseF

    L

    EgD ,ar braking

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