1. 5 S & P O K A Y O K E
03 July 2019, IndiaGautam Kumar
2. Learning Objective
1. Understand the benefit of working in clean &
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
3. WHAT IS 5S AND WHY DO WE WANT TO
• 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
• 5S is one of the activities that helps in any company’s operation.
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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
• Poka-yoke devices fall into two major categories:
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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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