Must Know Japanese

6 Quality Management Terms

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 Japanese Quality Management Terms

5’S/6’S 5W1H/2H 5G 7 MUDA 7 QC Tools

 Gemba  Check Sheet

 Sort  Who  T– Transport
 Gembutsu
 What  I–
 Control Chart
 Set in order  Genjitsu Inventory

 When  Genri  M– Motion  Pareto Chart

 Shine  Gensoku
 Where  W– Waiting  Cause & Effect
 Standardize  Why  O–
3M
Over Production  Histogram
 Sustain  How  O– Over Processing
 Scatter Plot
 How Many  Muda
 D - Defects
 Safety  Mura  Stratification

 Muri

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 5’S Origin What is 5’S Benefits of 5’S
 5S is a process and method for creating and maintaining an organized,clean & high performance
 Improved safety
Who : Sakichi Toyoda workplace.
(Father of Japanese  A clean, orderly workplace
Industrial Revolution)  5S enables anyone to distinguish between normal and abnormal conditions at a glance.
 Improved efficiency
 5S is the foundation for continuous improvement,zero defects, cost reduction, and a safe work area.
When : 1970’s  Increased employee morale
 5S is a systematic way to improve the workplace, our processes, and our products through production
Origin : Japan  Standardized work methods
line employee involvement.

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 What is 5W2H
 It is a management tool that helps in gathering Purpose
information about the problem and creating action
 Find out all important information about a problem so
plans. Application
that SMART definition of a problem can be made.
 It is a structured approach for understanding the
 Define what is problem and what is not problem.
root causes of problems.  It is generally used in "Define" phase of problem
 Limit the scope of problem solving.
solving in DMAIC six sigma project, while gathering
 Understand 360 degree view of the problem
information during ‘Problem Statement'

5W1H/2H

What What is the Problem? Goals,Objectives,actions,steps,description

Where Where is the problem? Location, Department

When When is the problem? Time,Date,Schedule,deadlines

Who Who is involved in the problem? Responsible Team for Action

Why Why is the problem? Justification,Reason,Benefits

How How is problem happening? Activities,Method,Process

How Much How many incidences? Cost,Quantity,Expenses involved

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 What is 5G? Purpose of 5G

 To describe a situation in a complete and detailed way.

 5G is Japanese concept(Gemba,Gembutsu,Genjitsu,Genri, Gensoku) is a tool used to
describe the loss phenomenon.  To keep a proper relationship between theory and
practice.
 It can be related to safety,Quality,Parts Shortage, Major Breakdown, Line stoppage and
etc.,  To follow a logical flow during the process

Gemba Gembutsu Genjitsu Genri Gensoku

Principle Of Standards &

Real Place Real Things Real Facts
Operation Parameters

Examine the Collect the data Check the physical Check the process
Go to the place conditions of characteristics,SOP,
machine, tools, and analyse and
where the problem machines, tools, WorkInstructions,OPL
equipment, objects also perform equipments and Verify it’s being followed
happened
to know the clues countermeasure the current practices or not
“First 3G’s are mainly focus of the team. They get the leaders or team to the shop floor instead of “Next 2G’s are necessary when the previous steps do not reveal
trying to solve the problem behind the desk” the causes of the problem”“

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