(Seiri) (Seiton)

(Seiso)
(Shitsuke)

(Seiketsu)
5S’ : A method for organizing a workplace, and keeping it
organized.

Benefits
1.Improve safety
2.Identify problems more quickly
3.Develop control through visibility
4.Decrease down time
5.Raise employee morale
6.Establish convenient work practices
 Before

After
 Visual Control
Any communication device used in the work
environment that tells us at a glance how work
should be done and whether it is deviating from the
standard
Benefits
1. Increase productivity
2. Improve quality
3. Increase equipment reliability
4. Reduce inventory
5. On-time delivery
6. Boosts bottom-line profits
 Kanban
• A system of continuous supply of
components, parts and supplies,
such that workers have what
they need, where they need it,
when they need it

“Kan” means visual, and

“ban” means card or board.
 JIT Just In Time
What is required, When is required, & How much is required

Three Pillars
1. Takt time

2. Make Process Flow

3. Pull Production System

 Takt time
Desired Time to produce one unit
Daily Operating Time
Takt Time =
Total Daily Production
480 mins./day
=3.2 mins./pc.
150 pc./day

“TAKT” is a German word meaning “Meter”

Metronome
 Make Process Flow
Lot Production Single piece Flow

・ Line Balancing
・ Process Sequencing
・Use Conveyor

・Line Balancing ・Process Sequencing

1st Process 2nd Process 3rd Process

・Use Conveyor
 Pull Production System
Produce only the quantity required by Next Process
Previous Process Following Process OEM

Information Information
KANBAN KANBAN KANBAN

Complete Elimination of Muda

(Minimize Inventory, Man Power and Machinery）
 Heijunka
• It is a technique for reducing the waste and is
vital to the development of production
efficiency in the Toyota Production System and
Lean Manufacturing. Here, the general idea is
to produce intermediate goods at a constant
rate, to allow further processing to be carried
out at a constant and predictable rate.
• Level Production by Quantity of Items
• Routinely received orders for 500 units/wk:
– 200 units on Monday
– 100 units on Tuesday
– 50 units on Wednesday
– 100 units on Thursday
– 50 units on Friday
• Level production at 100 units/day
• Leveling Production by Type of Goods
– Product A – 5 units/wk
– Product B – 3 units/wk
– Product C – 2 units/wk
– Product D – 2 units/wk
• Mass Production: AAAAABBBCCDD
• Lean Level Production: AABCDAABCDAB
Total Productive Maintenance
 SMED (setup reduction)
SMED focuses on reducing changeover and set-up
times, thus enabling organizations to:

Produce smaller lots of products and services more

frequently !
Develop a broader scope of products and services !
Reduce quality defects towards zero !

Meet Customer’s Expectations !

 Example of One Step Fastening

Bolt attachments requires 32

complete turns for each bolt or
screw (1 for each thread) to fasten This clamp attachment requires one
this bolt and die to a machine. step to attach the die to a machine.
 Poka-yoke or mistake proofing

• A techniques that help operators avoid mistakes in

their work caused by choosing the wrong part,
leaving out a part, installing a part backwards, etc.
 5Ws & 1 H

• It is a method of questioning
that leads to the identification of
the root cause(s) of a problem