26 Ago 5 GEN Methodology
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- 5 GEN Methodology is a very famous Japanese Method for problem-solving and various improvements activities related to manufacturing operations
- All five principles start with the word “GEN”, that´s why it is known as the 5 GEN Methodology or 5 GEN principles.
- This method is used for problem_solving and improvement projects.
- This method provides an efficient and effective solution
The 5 GEN Principles
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- GEN-BA
- GEN-BUTSU
- GEN-JITSU
- GEN-RI
- GEN-SOKU
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1.GEN-BA
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- Means “the actual place”
- Sometimes Genba is also used as Gemba, both names are the same.
- Gemba is a combination of two Japanese words Gen and Ba.
- In easy language, we can understand the Gemba as the real place where the incident happened
- In other word, we can say that Gemba is the place where we need to perform the improvement projects or the problem to be solved or some work to be done.
- As per the Gemba concept, we need to visit the actual place for problem_solving or perform any improvement.
- This is a very famous Japanese methos that is used in TPM Methodology, and Toyota production system.
- When we are facing any problem, then we need to go to the Gemba and observe the problem.
- We can also proactively find out the different 7 Types of Abnormalities by visiting the Gemba and it helps us to prevent failure.
2.GEN-BUTSU
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- The second G is known as Genbutsu
- GEN_butsu means the “Actual thing”
- Sometimes, Genbutsu is known as Genchi Gembutsu which means “go & see”.
- The actual thing might be a product, tool, or process that we need to improve or analyze.
- We can identify the correct root cause and make the right decision after visiting and understanding the actual thing at the actual place
- The team needs to observe the failed equipment or parts at the Gemba for problem_solving.
- This helps in identifying the actual root cause of the failure.
3.GEN-JITSU
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- GEN_jitsu means the “Actial condition”.
- GEnjitsu refers to the data and facts related to the problem or incident that happened.
- The actual condition is the most important thing for further analysis of the problem.
- We can compare the actual condition with the ideal or standard condition for identifying what´s going wrong or wright?
- By this study, we can easly access the real causes of the problem and we can take further actions on that.
- In this step, the team needs to gather all the data about the 4Ms that means data related to man, machine, materials, and method for analysis.
- It helps the team for identifying the actual root cause behind the problem.
4.GEN-RI
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- The fourth “G” stands for Genri.
- Gen_ri means “Principles” or “Theory”
- We need to understand the principles of theory of machines or any equipment before resolving the abnormality or problem.
- The principle of the machine helps the team for identifying the cause of the problem.
- With the help of the machine operating principle, the teams can access the machine running condition.
5.GEN-SOKU
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- GEN-soku means “Fundamental Rules, parameters or standards”
- For daily operations, we need to train all operators with the standard machine operating parameters.
- With the help of standard parameter, the operator maintains the machine in normal condition
- Most of the common reasons for the equipment failure is the deviation of the machine parameters from the standards.
- To eliminate machine breakdowns we need to train people with various standards like SoPs, OPLs, Work instructions, Process Parameters Standards, etc..
- Also, we need to display all standards documents near the machine so that they can be easily accessed by an operator.
- Also, we need to update all the standards after successfully problem_solving.
Benefits of 5GEN Principles:
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- Easily perform the Root Cause Analysis (RCA) for any problem.
- Identify and solve the abnormalities.
- It helps for the Standardization of the Operation across the Organization.
- It helps for the Problem Solving and various improvement projects.
- 5GEN principles improve the operator´s knowledge and problem_solving skills