Methodologies to improve manufacturing productivity and efficiency

In modern world time is money, more product you can produce in a period of time the more profit you make, because in this way you are using your resources and machine more efficiently. If you are struggling to improve your production then there are many modern methods and techniques by which you can increase your production without compromising the quality of product.


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Kaizen - Kaizen word is taken from Japanese language which means "Continuous improvement". In this strategy workers from all the levels work together to achieve incremental improvement to the manufacturing process. In other words it combines all the talent with in a company to create powerful engine for improvement.

The cycle of kaizen activity: "Plan → Do → Check → Act". This is also known as the Shewhart cycle, Deming cycle, or PDCA

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5S represents Japanese words it describes the steps involves in production or manufacturing process.

There are list of function under 5S.

1. Seiri (Sort)

2. Seiton (Straighten, Set)

3. Seiso (Shine, Sweep)

4. Seiketsu (Standardize)

5. Shitsuke (Sustain)

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5s Details

1. Seiri (Sort)

In this step we remove unnecessary things which we do not need.

Remove outdated material, waste material, broken equipment, and material which of no use. In this process we have to take help of staff and ask them to tag those items which they don’t think are needed, because only staff can clearly know which items they needed in the process.

Classify items by frequency of use to help decide which item have to be removed.

2. Seiton (Straighten, Set)

This step involves placing all necessary item in the optimal place. Goal of this step is to make workplace easy and smooth.

Arrange all necessary items/equipment in close proximity, so that they will be easy to reach. Place frequently used items close and in logical order, it will save lot of time of workers in finding correct tools during manufacturing process. Also assign fixed place for equipment also use marks so that item are easy to return to the correct place and so that it is easy to spot missing tools.

3. Shine (Seiso)

Clean workplace leads to refreshing experience for workers and improve their efficiency, because of clean workplace (without garbage, dirt and dust) it is easy to find defects in workplace like leaks, spills, damage etc.

4. Standardize (seiketsu)

Standardize the process used to sort, order and clean the workplace. This step established procedure to ensure repetition of first three 'S' practices

Make it a habit for everyone to perform sorting, organizing and cleaning, develop a structure that will accept new practices and make it part of the daily routine. Review and improve continuously status of 5S regularly

5. Sustain/Self-discipline (Shitsuke)

Sustain the developed process by establishing and maintaining responsibilities. This is the most difficult step of the process. Collective efforts leads to success of this step because every worker have to stick to the rules and make it his daily routine.

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