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5S Audit check sheets are separate check sheets for each of the 5S principles (Seiri, Seiton, Seiso, Seiketsu & Shitshuke). Read about all 5S audit check sheets. Add your company-related points to expand these check sheets. Audit Sheet: Seiri (Segregation) Checkpoints for Seiri: 1S S.No Check Items Description Score 0 1 2 3 4 5 … Read more
5S is a five-step program that is done in sequential order. 5S is a series of activities for eliminating waste that contributes to workplace rejections, mistakes and injuries. The Japanese factories are so clean that you can eat off the floor. This is simply a matter of pride for the Japanese. Below are the 5 … Read more
Poka-Yoke: Poka Yoke means Mistake Proofing or Error Proofing. Poka Yoke is a mechanism to prevent mistakes and defects from being made or detect mistakes if not prevented. It is also called error-proofing or foolproofing. Dr. Shigeo Shingo developed the concept of Poka-Yoke. Poka-Yoke is based on the concept that people do not make mistakes intentionally. … Read more
Kanban is a workflow management method focused on continuous improvement. It operates as a pull-based system, meaning tasks are pulled through each stage only when capacity is available, rather than being pushed through regardless of readiness. While commonly used in production, Kanban is adaptable to a wide range of processes. Its core purpose is to … Read more
Jidoka Jidoka is to build devices in the machines that detect defects and automatically stop the machine upon such an occurrence. When we give the power “to push buttons or pull cords” to operators is called Andon, which can bring the entire assembly line to stop. What is the difference between Andon and Jidoka? Jidoka … Read more
Value Stream Mapping: Value stream mapping is a method to check and improve the processes involved in delivering a product using flowcharts. The information and process flow from customer demand to delivery is examined by the VSM team. It is the main tool of lean manufacturing. Like other types of flowcharts, it uses a system … Read more
Categories of all activities: Value-added activities: The process is defined as the conversion of input into output by using resources. But what is important here is Value addition in the process. So those activities which change the shape as per customer requirements & add value are called value-added activities. For example in the manufacturing … Read more
In Lean manufacturing, the 3G principle—Gemba, Genbutsu, Genjitsu—is vital for resolving defects efficiently on the shop floor. By going to the real place, seeing real things, and understanding real facts, manufacturers drive meaningful improvements. Purpose of 3G: In manufacturing, encountering problems is inevitable. What truly matters is how quickly and effectively they’re resolved. The 3G … Read more