The document discusses the 5S principles and poka-yoke techniques. It begins by defining the 5S principles as a methodology originating from Japan for organizing and standardizing a clean and tidy workplace. The 5 principles are: Sort, Set in Order, Shine, Standardize, and Sustain. It then discusses how to implement 5S initiatives through activities like monthly reviews and appreciation. It also defines poka-yoke as a technique to eliminate mistakes through prevention and detection methods. Examples provided are designing processes to decrease complexity and making wrong actions more difficult. The goal is achieving zero defects through low-cost improvements to processes.

1. 5 S & P O K A Y O K E
Gautam Kumar
03 July 2019, IndiaGautam Kumar

2. Learning Objective
1. Understand the benefit of working in clean &
neat environment.
2. Define the 5S Principle & Identify visual tools
3. Explain how to apply the 5S principles & visual
tools to enhance office organization
4. Learn how to kick start & launch 5S initiative
5. Define the critical success factor for 5S
implementation

3. WHAT IS 5S AND WHY DO WE WANT TO
DO IT?
• 5S was developed in Japan and was identified as one of the techniques that enabled Just in
Time manufacturing (TPS - 5S, kaizen, kanban, jidoka, heijunka, and poka-yoke.).
• These are foundational to Kaizen (continuous improvement) and a manufacturing strategy
based "Lean Manufacturing" (waste removing) concepts.
• 5S is short for: -
• SEIRI – Sort
• SEITON – Set in Order
• SEISO – Shine
• SEIKETSU – Standardize
• SHITSUKE - Sustain
• 5S represents 5 disciplines for maintaining a visual workplace (visual controls and
information systems).
• 5S is one of the activities that helps in any company’s operation.
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Findings in Office

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14. HOW TO
SUSTAIN?
• Get everyone involved
• Promote 5S
• Gemba Walk
• Monthly review by 5S committee
• Appreciation
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16. POKA-YOKE (MISTAKE PROOFING)
• Poka’ means ‘Mistakes’ & ‘Yoke’ means ‘Avoid’. It’s objective is to achieve Zero Defects. Term adopted by Dr.
Shigeo Shingo as part of the Toyota Production System in 1960.
• The real world
– People make mistakes
• People are human
• Mistakes are inevitable
• People always make mistakes.
• -While we accept the mistakes as natural, we blame the people who make them.
• -With this attitude, we are likely to overlook defects as they occur in production.
• -They may be detected at final inspection, or worse still, by the customer
•
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17. • DEFECTS AND ITS IMPACT
• • Defect free product is a necessity to compete in the market place.
• • Every Customers has a right to demand 100% good product /service and every provider
has an obligation to provide the same.
• • Bad products hurt both reputation and bottom line (Scrap, rework, warranty….etc.,.)
• • Defects have a direct impact on process yield affecting speed and flow of the product to
the customer
• Poka-yoke devices fall into two major categories:
– Prevention
– Detection
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18. • Murphy’s Law: “If something can go wrong it will”
• The old way to prevent mistakes
– Retrain worker
– Motivational talks
• Tell them to “be more careful”
• Tell them to “pay attention”
• A better way to prevent mistakes
– Remove the opportunity for error
• Improve the process
• Make wrong actions more difficult
• Design process to decrease complexity
– If you can’t remove the opportunity for error
• Make it easier to discover the errors that do occur
• Eliminate unnecessary or duplicate steps
– Use flow charts to visualize the process
– Follow ‘just-in-time’ principles by only making what is needed, when it is needed in the amount needed.
You don’t have to spend a lot of money
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20. Thank you