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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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