These are Best in-house practices followed on shop floor while working in industries. By adopting these (5S, 3M, 3K & 3G) Japanese philosophies, we can sustain best manufacturing quality. Each word has its meaning & practices to follow.
3M– MUDA, MURI & MURA
5S– Seiri, Seiton, Seiso, Seiketsu & Shitsuke
3G– Genchi, Genbutsu & Genjitsu
3K– Kimeraareta, Kihon Dori & Kichin to mamora
Understanding 3M
3M stand for – MUDA, MURI & MURA
- MUDA – Waste
- MURI- Overburden
- MURA– Unevenness
These are Japanese terms that refer to the three categories of waste found in a business. MUDA (Waste) + MURI (Overburden) = MURA (Unevenness)
- MUDA is a thing of MURA.
- MURI will also be looked for if MUDA is found MUDA will also be looked for if MURI is found.
There are 8 types of waste in lean manufacturing. Which can be remember by word- DOWNTIME.
- Defect
- Overproduction
- Waiting
- Non-utilizing talent
- Transportation
- Inventory
- Motion
- Extra-Processing
Understanding of each waste in business
Defects: – A product that is not meeting specification or customer satisfaction. It is very common waste in industry. Impact of defect
- Cost of defective product
- Quarantine stock
- Reinspection
- Customer dissatisfaction
Overproduction: – Production of larger quantities before necessary. It is Most expensive waste. Cause of overproduction- Wrong sales forecast, Production at maximum capacity to maximize used of machine.
Waiting: – Occurs when goods are not moving or not processed. Common reason of waiting.
- Poor material flow, capacity blockage
- Machine breakdown
- Long Production changeover time
Non utilizing talent: -Loss of ideas, skills, improvements, learning opportunities by not hiring or disobeying your own employees. This happen when employees time & skill are not being used properly, less authorities & limited liabilities.
Transport: – It is related to excessive movement and handling of material over long distances. Waste due to transport could be due to inadequate transport equipment/Technique, Large batch management, long distance between process.
Inventory: – Occurs when there is unnecessary level of raw material, WIP, Finished goods, tools and resources.
Motion: – Physical movement that employees exercise excessively among other reasons due to a lack of planning in the ergonomic field, providing low productivity and muscle fatigue. Walking, reaching something, searching & sorting.
Extra processing: – Providing higher quality or more control than necessary. Overprocessing will lead to more rejection in process.
Overview of 5S philosophy
5S stand for 5 Japanese word- Seiri, Seiton, Seiso, Seiketsu & Shitsuke
- Seiri- Sort
- Seiton – Set in Order
- Seiso – Shine
- Seiketsu -Standardize
- Shitsuke -Sustain
The 5S methodology is a critical approach for enhancing workplace organization. It consists of five steps: Sort, Set in order, Shine, Standardize, and Sustain. Each step is designed to eliminate waste and inefficiency, ensuring that the workspace is clean, organized, and efficient. By implementing 5S, businesses can achieve greater productivity and improved work standards.
SEIRI– SHORT (Remove unnecessary clutter, remove item which are broken & Unusable).
SEITON– SET IN ORDER (Organize layout of Tools & Equipment, ensure everything is available as it is needed at the point of use).
SEISO– SHINE (Create a spotless workplace. Identify and eliminate dirt & grime from tool & equipment).
SEIKETSU– STANDARDIZE (Maintain system of first 3S, Fill check sheets. Make SOP/WI for regular audit & measure of housekeeping).
SHITSUKE– SUSTAIN (Inoculate courtesy & Good habits, regularly maintain all 5S & make its way of life to make healthy & safe work environment).
Benefits of 5S implementation is cost reduction & reducing waste in manufacturing process. It creates healthy & good atmosphere on workplace. Improve production efficiency & provide customer satisfaction on long terms.
Understanding 3G
3G stand for 3 Japanese words- Genchi, Genbutsu & Genjitsu
- Genchi – Actual Place
- Genbutsu– Actual Thing
- Genjitsu– Actually
It means “In case of an abnormality, all the concerned members should actually go to the place where the problem has occurred, see the actual thing & take realistic action to solve the problem”. It is 3 reality principle.
3 reality principles are used in research & problem-solving techniques. These principle instruct to:
- Go to the Actual place [Genba]
- Know the actual situation (By touching, seeing & being in contact with actual element)
- Be realistic (After gaining information from actual place and actual contact one must be realistic in his assessment)
What benefits will come if we adopt this 3G Principle?
With this we will have correct information & actual problem details. It helps in solving problem at workplace. In some situation we miss some information and start analysis, which lead to unconclusive result.
Understanding 3K
- Kimeraareta- What has been decided
- Kihon Dori- Exactly as per standard
- Kichin to mamora- Must be followed
It means “What has been decided must be followed exactly as per the standard”. This concept is displayed prominently at workplace across company. These 3K words talks about there should be WI/SOP at each workstation. Work should be done as per Work instruction or SOP. Anything beyond SOP will lead to defect.
Why this is helpful?
Well adhering SOP ensure stable work process. Usually nonadherence of SOP creates errors which result of defect in process. With this we guarantee that product passed from standard work of process.
Implementation Strategies of 3G, 3K, 3M & 5S
These strategies are essential for effectively implementing 5S, 3M, 3K, and 3G in any organization.
| Strategy | Description |
| Training | Provide training sessions to staff on 5S principles. |
| Regular Audits | Conduct frequent audits to ensure adherence. |
| Management Support | Secure commitment from leadership for success. |
| Engagement | Encourage continuous feedback from employees. |
| Integration | Embed methodologies in daily operations. |
Conclusion
In conclusion, this post highlighted the principles of 5S, 3M, 3K, and 3G methodologies. Each plays a crucial role in enhancing organizational efficiency and effectiveness. Understanding these tools can lead to significant improvements in workplace productivity.
All comments Q&A are welcome, we invite you to share your questions or insights on these methodologies to further enrich our discussion.
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