The document discusses several quality and manufacturing concepts including the 5S methodology (Sort, Set in Order, Shine, Standardize, and Sustain), Kaizen (continuous improvement), TPM (Total Productive Maintenance), WCM (World Class Manufacturing), Six Sigma, Poka Yoke (mistake proofing), SMED (Single Minute Exchange of Die), Lean Manufacturing, QMS (Quality Management System), and the Plan-Do-Check-Act cycle. It provides definitions and key aspects of each concept to help organizations implement quality initiatives and improve manufacturing processes.

1. Allied Quality Concept..
Presented by Rahim Khoja
(April 2015)

2. FIVE ‘S’
• S : SEORI ( SORT ) - To organize or reorganize and throw away
unwanted things from your work place.
• S : SEITON ( SET in ORDER) –To fix place for every thing and
every things keep in it place.
• S : SEISO ( SHINE or CLEANING) – To Clean and make shine
your work place.
• S : SEIKETSU ( Standardize) – To standardize the way of storage
all thinks in your work place.
• S : SHITSUKE ( SUSTAIN) – To make sustain by discipline.
Sustain
Standard
Shine
Set
Sort

3. KAIZEN
• KAI meaning Change and ZEN meaning GOOD (for better)
• KAI +ZEN meaning to make good change for continual improvement
• Type
• Individual oriented kaizen and Group oriented kaizen, e.g. quality circle
• Gemba Kaizen , e.g. change in work place or in items.
• Kaizen Blitz for breakthrough improvements
Combination of Muri (strain) , Mura (inconsistency), Muda ( Waste) with MEN ,
Material , Machine , Method will give opportunities for Kaizen.
Muri ,
Mura,
Muda
Men,
Material,
Machine, Method
Kaizen

4. TPM
• TPM stand for Total Productive Maintenance
• It is a system of maintaining and improving productivity by plant and equipment with
a modest investment in maintenance that add business value to organization.
• The eight pillars of TPM focused on proactive and preventative techniques for improving
equipment reliability
• They are ‘Autonomous Maintenance, Planned Maintenance, Quality Maintenance,
Focused Improvement, Early Equipment Management, Training and Education, Safety
Health Environment, TPM in Administration’.
• Overall Equipment Effectiveness of plant equipment measured by multiply of factors
Performance, Availability and Quality.
• Performance Downtime, Delay ; Availability- Breakdown, Changeovers; Quality 
Reject, Repair, Reprocess.

5. WCM
• WCM stand for WORLD CLASS MANUFACTURING
• It is in-depth analysis of Japanese manufacturing methodology and assists
the participants to acquire a better understanding of -
• TQC (Total Quality Control),
• TQM (Total Quality Management),
• TPM (Total Productive Maintenance),
• JIT (Just In Time),
• TIE (Total Industrial Engineering) practices and
• KAIZEN (continuous improvement).
TPM
TQM
Kaizen

6. SIX SIGMA
• It is statistical measure of variation indicated by
standard deviation – Six sigma.
• The performance of process are measured at 3
sigma , 4 sigma and etc.
• At 6 sigma , performance level means defects
in process is not more than 3.4 part per million
• Six Sigma is management tools to achieve
defect less system to reduces cost and waste
resultant in satisfaction of customer.
• It realized “FIRST TIME RIGHT QUALITY
PRODUCTS” should be manufactured.
2 3 4 5 6 7 8 9 1210 16151413111
LSL USL
6 Sigma curve
3 Sigma curve
3 Sigma Vs 6 Sigma

7. Poka Yoke
• It refers to techniques that make error proofing by mistakes. It can be thought
as an extension of Failure Mode Effective Analysis.
• For developing and implementing cost-effective error or mistakes proofing
devices help on innovative problem-solving techniques , e.g. interlocks
Y
POKA
E

8. SMED
• SMED means Single Minute Exchange of Die, was developed in the
automotive sector. Originally used in press shop to improve tool (die)
setup time. It is technique used for radically reducing “changeovers”
of any kind.
• SMED is structured methodology. In 1950 at Toyo Mazda presses,
Dr. Shingo examined die change operation. A missing mounting bolt
was replaced removing a long bolt from other press and machined
to size.
• The idea of “internal setup” and “external setup” clicked to be
completed in less than 10 minutes i.e. single digit , 1 to 9 minutes,
called SMED tool.
Process 1
Stop
Process 2
Stop
Start
Process 3 …

9. LEAN Manufacturing
“If it does not add value, it is waste”. This
concept revealed by Henry Ford, and later it
was adopted by TOYATO.
An eight non-value-adding wastes can removed from process.
Over production, Waiting, Un necessary transport,
Over processing, Excess inventory, Unnecessary
movement, Defects, Unused employee creativity
Waste

10. QMS
QMS stands for Quality Management System
ISO 9001 :2008 standards explained by SCOPE, NORMATIVE
REFERENCE, TERMS AND DEFINITIONS, QUALITY
MANAGEMENT SYSTEM, MANAGEMENT RESPONSIBILITY,
RESOURCE MANAGEMENT, RODUCT REALISATION,
MEASUREMENT ANALYSIS AND IMPROVEMENT.
Auditing tools strengthen system through FIRST PARTY AUDIT,
SECOND PARTY AUDIT, THIRD PARTY AUDIT, SYSTEM
AUDIT, PROCESS AUDIT, PRODUCT AUDIT.
Plan
DoCheck
Act
Continual
improvement

11. Thank You..
e-mail : rahimkhoja82@outlook.com