5S

5S HOUSE KEEPING
5S is a practice of housekeeping used to establish and

maintain a productive and quality environment

Well organized workplace safer, efficient & more productive

environment

OBJECTIVES OF 5S
To create a clean & neat working place
To systematize day to day work
To improve work efficiency
To standardize work practices
To improve work discipline
To improve quality of work & products

FACTORS IN IMPLEMENTING
5S
1. Participation by all
2. Top management commitment
3. Should be self sustaining
4. Review the program

BENEFITS?
Simplification of process
Increases material visibility
Re energizes work force
Improves quality management
Clean & safe work environment
Increases efficiency of operations

DISADVANTAGES
Time consuming
Inappropriate starting point
Loss of effectiveness

QUALITY CIRCLES

INTRODUCTION
QC is a voluntary group
6-10 people from various departments
Meet every fortnight or periodically
Lead by Quality Leader & members are called QC Members
Once formed sets their own reference, standards, terms, etc.
No extra compensation will be given

CHARACTERISTICS OF QC
Voluntary membership
Training
Problem soling
Group process
Continuous process
Management support
Recognition

DEVELOPING QC
Start up phase
Constitution of QC
Initial problem solving
Presentation & approval of suggestions
Implementation

TECHNIQUES USED FOR

DISCUSSION IN QC
Brain-Storming
Cause & Effect
Sampling & Charting

ADVANTAGES?

8D
METHODOLOGY

INTRODUCTION
Problem solving method for product & process improvement
Eight disciplines emphasizing team synergy
Effective in developing proper actions in order to eliminate

root causes & implement permanent corrective action

Pioneered by Ford Motor Company

OBJECTIVES:
Structured problem solving & corrective action
Understand importance of finding root cause
Understand waste & process control
Use of statistical tools for problem solving
Develop action plans to perform problem solving

8 D (DISCIPLINES)
1. D 1 Establish the team
2. D 2 Describe the problem
3. D 3 Develop interim containment actions
4. D 4 Define & verify root cause & escape points
5. D 5 Choose & verify permanent corrective action
6. D 6 Implement permanent corrective action
7. D 7 Prevent recurrence
8. D 8 Recognize team & individual contribution

BENEFITS
Useful in product & process improvement
Effective approach
Combination of techniques
Additional benefits

LIMITATIONS
Time & effort consuming
Does not solve the problem
Requires training
Resource consuming

TAGUCHIS
CONTRIBUTION

INTRODUCTION
Engineer & Statistician
Made a lot of contribution to industrial statistics
Advocated that the design of the product should be robust

enough such that it doesnt get affected by environmental

factors

Important contribution is the QLF

CONTRIBUTIONS
1. Quality Loss Function (QLF)
2. Orthogonal Arrays
3. Quality Engineering
4. Signal to Noise Ratio

1. QUALITY LOSS FUNCTION

Statistical methods developed by Genichi Taguchi
Aims to improve quality of manufactured goods
Contradictory to many western methods
Contributions include:
1. Taguchi loss function
2. Philosophy of off-line quality control
3. Innovations in design of experiments

TAGUCHI LOSS FUNCTION

Taguchi defines quality as the loss impaired by the product to

society from the time product is shipped

Loss includes cost to operate, failure to function, maintenance

& repair costs, customer dissatisfaction, injuries caused by

poor design & similar costs

Defective parts before shipment are not considered as part of

this loss

Whenever a product deviates from its target performance, it

generates a loss to society

TAGUCHI VS TRADITIONAL
APPROACH
Consider two products
One within specified limit & other outside limit
Traditional approach one within limit is good & outside limit is

bad

Taguchi when a product moves out from its limit it causes

losses

TAGUCHIS QUADRATIC
QUALITY LOSS FUNCTION

QLF
L(x) = k(x-N)^2
L(x) loss function
k constant of proportionality
x quality characteristic of selected product
N Nominal value of chosen product
(x N) - tolerance

2. QUALITY ENGINEERING
Uses designed experiments to improve product & process

quality

Engineers have to achieve ideal product function

Products designed to reduce losses.
Three stages:
A. Systems design
B. Parameter design
C. Tolerance design

A. SYSTEMS DESIGN
Conceptual design stage
Scientific & Engineering expertise is applied
Under normal conditions, original & new technology systems

are developed

Less focus compared to other stages

B. PARAMETER DESIGN
Robust design cornerstone of Taguchis philosophy
Three product development stages:
1. Product design
2. Process design
3. Production
.Only at product design counter measures are possible against

all sources of variations

.Parameter design selection of optimum conditions so that

product is least sensitive to variations

C. TOLERANCE DESIGN
Tolerance studies to determine the variables which have

critical tolerances that need to be tightened

Systematic procedure of identifying crucial noise factor &

suggests the most cost effective way to control it

Natural impulse that quality can be improved by tightening

tolerance

3. SIGNAL TO NOISE RATIO

Statistical

performance measure tool developed by Taguchi

Simply the ratio of mean (signal) to the standard deviation

(noise)

=
Eg: Car braking