5S & POKA YOKE

Gautam Kumar
03 Gautam Kumar
July 2019, India
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
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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 HOW TO
SUSTAIN?
• Get everyone involved
• Promote 5S
• Gemba Walk
• Monthly review by 5S committee
• Appreciation

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 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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• 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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• 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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Thank you