This document discusses a problem at an Indian textile company where water is being wasted. The problem is that during the dye mixing process, the operator opens a tap to wash their hands but the tap is far away, so they leave it running by using an extra pipe. This wastes water. Using the 5K method to analyze the problem: 1) The real problem is water wastage. 2) The root cause is the tap location. 3) The best solution is to install a new pipeline near the weighing area. 4) The job will be completed within an agreed upon time. 5) The responsible person is named to oversee the project.

1. Prepared by
Sachin Sahu
Engineer
Indian Rayon

2. Why needed this technique
Q.1 There are so many problem finding technique in the
market why there is a need of a new one.
Answer is simple , There is always a need of new one just
kidding, real answer is that this method contain a
powerful factor which is missing in most of the methods
is the 5th K of this method which account for
responsibility.

3. K stand’s for
 1 k for Kya /what
 2 k for Kyu /why
 3 k for Kaise /way
 4 k for Kab /when
 5 k for Kon/ who

4. 1 K / W
1st k of this method representing the Hindi word kya /What here it
has importance in real defined problem
 For Ex :- If some one saying water tap not working it’s a problem
but not a real one
 Real problem is that what’s the major affect by it
 So real problem in this case is WATER WASTAGE
This first k headed our mind towards real problem

5. 2nd K / W
 2nd k of this methods representing the Hindi word kyu /
why
Here it is used for finding root cause of the problem
For finding root cause there are several means like why why
analysis , Fish bone diagram E.T.C these analysis can be used
for major problem otherwise experience / technical
knowledge are also valid

6. 3rd K / W
3rd K of this method stand for Hindi word kaise/ways here it is
showing what is the best method to solve the problem.
 There are many ways to solve a problem but the best one is
comes after cut off all ties mainly to be : -
 1.Safe
 2. Cost Effective
 3.Higher Sustainable
 4.Maximum Output drivin
 5.Appropriate time consuming

7. 4th K /W
 4th k of this method stands for Hindi word kab/when here
it is stands for time reference
 What is the Average time required for providing best
solution in effect.
 Time boundation is the best way for doing things on time it
requires both effort & commitment.

8. 5th K /W
 5th K of this method stands for Hindi word kon / who Here
it is representing the authorized person/Body who has a
responsibility for completing this desired solution any how
in time.

9. Case :-
There is a company named as Indian Rayon situated at Veraval
(Gujarat) it is a renowned name in VFY production, there is a dept.
name PSY spinning(p) in it which contain many units itself
including its own dye unit where various colour dye batch prepared
as per customer demand. In colour dye preparation 2 or more
colour mixed in a definite proportion. Each time the particular
colour dye used helper has to wash his hand as per SOP for this he
opens the tap, but the location of tap is far from weighing machine,
so he uses an extra pipe present there already this extra pipe also
uses for tanks washing. The helper opens the tap and start mixing
colour one by one as per requirement each time he uses a new dye
he has to wash his hand & the tap remains open until the required
colour batch is prepared.
It is in notice to all the senior person but all of them searching for a
best solution possible of this serious matter
Q :-Find the abnormality in it & Provide best possible solution of
this case by using 5K method

10. Case Study
 Problem :- In dye room of a company name Indian
Rayon Veraval each time a mix dye batch prepared A
tap is opened for hand wash and it remains open till
the weighing of mix dye completed.
 1 K finding Real problem
 Real problem :- A handsome amount of water going in
drain simply WATER WASTEGE

11.  2nd K is to find out why it is happening
From day to day experience someone finds out
Water Tap is far from the weighing area forcing operator to
use extra pipe for his comfort.
 3rd K is to find out best possible way of solving
problem
Solution suggested by various body
1. An extra tap should be provided at tail end of pipe.
2.Operator should be instructed for not using the extra pipe
each time he should come near the tap for hand washing.
3. Provide an extra permanent pipeline near weighing
balance.

12. Finding best out of them
1st solution is generating an extra unsafe activity.
No need to further analysis as safety cannot be compromised
2nd solution is Safe, installation cost is zero, but not
sustainable as it is against human nature , output maximum,
time consumption nil.
3rd Solution is Safe, one time investment under limit, Highly
sustainable, output maximum , time consumption variable
but less.
Best possible solution is 3rd one as it is sustainable with some
extra cost.

13.  4th K is about kab when the job is completed
After agreement with the service providing bodies the
job is completed with in ------ time & in desired manner
 5th K is for responsibility
Mr. XYZ from the side of affected body upper
management team has the overall responsibility to get
the job done on time and to communicate with service
providing body for the on going job status