The document discusses 5S principles and the 8 disciplines of problem solving. 5S principles were developed in Japan and include Sort, Set in Order, Shine, Standardize, and Sustain to create a better working environment and consistently high quality processes. The 8 disciplines of problem solving include Plan, Use a Team, Define the Problem, Develop Interim Containment, Determine Root Causes, Choose Permanent Corrections, Implement Corrective Actions, and Take Preventive Measures to identify, correct, and eliminate recurring problems following the PDCA cycle. Both methods aim to improve processes, productivity, and quality.

1. 5S PRINCIPLES
THE SECRET TO
JAPANESE SUCCESS
U.KALPANADEVI
II- MBA
MICHAEL INSTITUTE OF MANAGEMENT

2. • Developed by the Japanese
• Housekeeping System
• Helps Create a Better Working Environment
and a Consistently High Quality Process

3. DELIVERY
SERVICE

4.  IF WE CANNOT KEEP OUR
WORKPLACES
 CLEAN
 ORDERLY
 ACCIDENT FREE
 NOBODY WILL BELIEVE WE CAN
PRODUCE QUALITY GOODS OR
ATLEAST SERIOUS ABOUT
PRODUCING QUALITY.

5. • SEIRI – Organisation/Sort out
• SEITON – Orderliness/Systemize
• SEISO – The Cleaning/Shining
• SEIKETSU – STANDARDIZE
• SHITSUKE - Sustain/Discipline

6. Sort Means That You Remove
All Items From the Workplace
That Are Not Needed for Current
Production Operation.

7.  A WORK ENVIRONMENT IN WHICH
 TIME
 MONEY
 SPACE
 ENERGY &
 EFFECTIVE RESOURCES MANAGMENT
 PROBLEMS IN WORK FLOW ARE REDUCED,
COMMUNICATION IS IMPROVED, PRODUCT
QUALITY IS INCREASED & PRODUCTIVITY IS
ENHANCED.

8. WASTE
ELIMINATION
LEADS TO
COST
OPTIMIZATION &
MANAGEMENT
EXCELLENCE

9.  Set in Order Can Be Defined As
Arranging Needed Items So
That They Are Easy to Use and
Labelling Them So That They
Are Easy to Find and Put away.

10.  WASTE OF
MOTION
SEARCHING
HUMAN ENERGY
EXCESS INVENTORY
DEFECTIVE PRODUCTS
UNSAFE CONDITIONS

11.  DECIDING APPROPRIATE LOCATIONS
 LOCATE ITEMS IN THE WORKPLACE
ACCORDING TO THEIR FREQUENCY OF USE
 PLACE FREQUENTLY USED ITEMS NEAR THE
WORKPLACE
 STORE INFREQUENTLY USED ITEMS AWAY
FROM THE PLACE OF USE.
 A LET GO ARRANGEMENT FOR TOOLS SO
THAT THEY GO BACK TO ORIGINAL PLACE OF
STORAGE

12.  Shine Means Sweeping
Floors, Whipping off
Machinery, and Generally
Making Sure That Everything
in the Factory Stays Clean.

13. This step eliminates Dirt, Dust and other
foreign matter to make the workplace clean.
Clean Equipment,Furniture,Notice Boards
Records Etc.
Keep the workplace Spotless.
Sweeping,wiping,polishing,painting Etc.

14.  Standardize Is The Result
That Exists When the First
Three Pillars - Sort, Set in
Order and Shine Are
Properly Maintained.

15. Set in Order
Machinery
Where
Things
Are Kept
OPERATION
Critical
Processes
Communication
Inventory

16. STANDARDIZATION
 PROVIDE OBJECTIVES AND INDICATE
TRAINING GOALS.
 PROVIDE A BASIS FOR TRAINING
 CREATE BASIS FOR AUDIT AND
DIAGNOSIS.
 PROVIDE A MEANS FOR PREVENTING
RECURRENCE OF ERRORS AND
MINIMIZING VARIABILITY.

17.  Sustain means
making a habit of
properly maintaining
correct procedures.

18. THIS STEP IS TO ENSURE THAT EVERYONE
STICKS TO THE RULES SCRUPULOUSLY
AND MAKES IT A HABIT
CREATE GENERAL AWARENESS ABOUT
4S.
TRAINING TO EVERYONE.
 DEVELOP NORMS AND MONITOR
SUCCESS.

19.  High employee Morale.
 Involvement of People in the Movement.

20. Let us create our own work place
with our own hands. Let us
contribute to a cleaner work place.
6th. S is now included as
“SHIKKARI YAROU” -- “let us try
hard”.
Every person should show
initiative and make a special effort.

21. 8 DISCIPLINES
OF PROBLEM SOLVING

22. HISTORY
 was created by U.S Department Of Defence
(DOD) in 1974.
 Standard was officially abolished in 1995, but
the 8D methodology has been propagated by
ford in the Automotive industry and is well
known to many companies in the electronics
industry.

23. PURPOSE
 To identify , correct & eliminate recurring
problems.
 It is useful in product and process
improvement.
 It follows the logic of PDCA cycle.

24. 8 DISCIPLINES:
D0: PLAN
D1: USE A TEAM
D2: DEFINE & DESCRIBE THE PROBLEM
D3: DEVELOP INTERIM CONTAINMENT PLAN; IMPLEMENT &
VERIFY INTERIM ACTIONS
D4: DETERMINE, IDENTIFY AND VERIFY ROOT CAUSES &
ESCAPE POINTS
D5: CHOOSE & VERIFY PERMANENT CORRECTIONS(PCs)
FOR PROBLEM/ NON – CONFORMITY
D6: IMPLEMENT AND VALIDATE CORRECTIVE ACTIONS
D7: TAKE PREVENTIVE MEASURES
D8: CONGRATULATE YOUR TEAM

25. D0: PLAN
Plan for solving the
problem & determine the
pre requisities.
D1: USE A TEAM
Establish a team of
people with product /
process knowledge.

26. D2: DEFINE & DESCRIBE THE PROBLEM:
Specify the problem by identifying
quantifiable terms for the problem.
D3: DEVELOP INTERIM CONTAINMENT PLAN;
IMPLEMENT & VERIFY INTERIM ACTIONS:
Define & implement containment
actions to isolate the problem from any
customer

27. D4: DETERMINE, IDENTIFY AND VERIFY ROOT CAUSES &
ESCAPE POINTS:
Identify the problems thst explain the
problem
D5: CHOOSE & VERIFY PERMANENT
CORRECTIONS(PCs) FOR PROBLEM/ NON
– CONFORMITY:
Through pre production programs
quantitatively confirm the correction

28. D6:IMPLEMENT AND VALIDATE
CORRECTIVE ACTIONS:
Define & implement the best
corrective actions
D7: TAKE PREVENTIVE MEASURES:
Modify the management systems,
operation systems, practices 7 procedures to
prevent the recurrance of similar problems.

29. D8: CONGRATULATE YOUR
TEAM: Recognise the
collective efforts of the team .
The team needs to be formally
thanked by the organisation.