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A Practical Approach To The Successful Practice Of 5S
By Tony Jacowski

In real terms, 5S can be described as a complete quality improvement system that aims at making continuous improvements in the immediate work environment as well as in the work conditions. To understand how it actually works, let us study each one of the given methodologies in detail:

Seiri

The Japanese word Seiri basically means ‘to sort’ and as such the given methodology deals with sorting out the equipment associated with a workplace. The sorting is done to identify and remove all the unnecessary items from the workplace so as to achieve a higher level of efficiency.

The sorting is based on the simple logic that items that are used every hour and every day should be kept within arms reach; items used once or twice a week or month should be kept within the work area; and items used even more infrequently should be kept in a more distant location. Apart from these, items that are tagged as unnecessary should be completely removed from the workplace.

Seiton

Systematize, or Seiton in Japanese, this methodology basically aims at putting the required items at appropriate places. This is done by using a workflow analysis chart that indicates all the items that will be required for a given process in a systematic order. Sometimes, inputs and suggestions sourced from the employees are also used for placing the required items in appropriate places.

Seiso

Sweep, or Seiso in Japanese, aims at keeping the workplace clean and fully functional year round. Equipment and other mechanical items are cleaned and inspected regularly to ensure that production is not affected by small problems. For most items, the cleaning and inspection is to be done on a daily basis, but if the organization feels otherwise, it can create a cleaning and inspection schedule based on the cleaning requirements of individual pieces of equipment.

Seiketsu

Standardize, or Seiketsu in Japanese, this methodology aims at developing visual controls and guidelines in order to keep the workplace organized and clean. The purpose is to achieve a level of standardization that can then be implemented on a daily basis. The standardization process is heavily dependent on the 3S explained above and as such it is necessary to ensure that the 3S have been properly taken care of before implementing Seiketsu.

Shitsuke

Self-Discipline, or Shitsuke in Japanese, this methodology aims at making the employees aware of the 5S by providing them training at regular intervals. It is based on the logic that the 5S will deliver results only when employees extend their full cooperation and support, something that can only be achieved through regular training and guidance.

When 5S is implemented, it helps in increasing the morale of employees, a prerequisite for achieving higher levels of efficiencies. Once this is done, the organization can then easily hope to reduce wastage, improve quality and facilitate faster lead times, all of which are necessary for the success of any business organization.

Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solutions - Six Sigma Online, http://www.sixsigmaonline.org, offers online six sigma training and certification classes for lean six sigma, black belts, green belts, and yellow belts.

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5S Implementation Is Truly Worth It
By Randy Hough

5S implementation is one of the smartest things you can do for your business, without a doubt. Your clutter will vanish, you will know where every single thing is in your shop, and everybody will be happier and more productive. What more could you ask for!

Seriously, if you have not made the 5S program part of your daily operation, do it now. There is really no reason to delay, unless you are already highly organized and efficient. It could be that some exceptional manufacturing shop is just naturally that way, it does happen, but rarely.

There are obviously 5 parts to the program, sort, straighten, sweep, standardize and sustain. Once you have understood the concepts and decided to implement them, you will almost immediately see results, really.

How it works in real-life

The first time I was involved in a 5S training program was with a typical American plastic injection molding shop of about 10 mold makers. We had been in business as long as plastic molding was a business, so there was a lot of ” stuff” laying around. It seemed that everything had a place, but only a few knew the secrets of where it all was.

I was highly skeptical of this idea at first because I had spun my wheels for so long on every new program that the managers learned at the latest seminar. Most of these programs just took our time and yielded little or nothing in the way of results. When I heard that it was Japanese, I got interested. At the time, they were decimating our auto industry and I figured they must know something we didn’t.

What do you need to get started?

Not much, mostly time and a will to do it. Once you learn the technique, it is a matter of educating your workers of the benefits and making it a permanent policy. It is essential that the decision come from the top down, otherwise it will be just another well-meaning program.

How long will it take?

It tookus about a week to actually finish the process. By the end of two days we had made a lot of progress, but it was essential that we complete the project entirely. I’m certain that things would have returned to “normal’ if we had not followed all five steps. It is very difficult to change a shop culture, but it can be done.

There were some guys who were very negative, but once they began to see the results their complaints disappeared. Is it worth the effort? Yes, it is very much well worth the effort. The time spent as you implement 5 S will most certainly pay for itself in a short time. If you only added up the hours spent looking for things, you would quickly justify the expense; not to mention the satisfaction you feel from working in a well-organized and efficient environment.

5S is just one part of the lean manufacturing process. It is also essential that everyone follows through, so the benefits can be permanent. It is not enough to paint some outlines of wrenches and then leave them laying about randomly.

Make sure you have your workers involved.

Assign various people to “be in charge” of different areas. They will take pride in the ownership of their work area and watch over it like a watch dog. In this way your shop culture begins to improve and moral will almost instantly improve.

Randy Hough

Plastic Injection Mold Maker

http://www.global-plastic-injection-molding.com

“You know Dad, I’ve been thinkin’, one is a lot more than zero!” my son, Thomas, age 5.

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5S Implementation Methodology
By Randy Hough

5S implementation methodology is a system to reduce workplace waste and optimize productivity by
maintaining an orderly workplace. The use of visual reminders helps to achieve consistent
improvements as well. 5S Implementation “cleans up” and organizes the workplace, without changing
its existing configuration, and it is typically the first lean method which an organization puts
into effect.

The 5S pillars, Sort, Straighten, Sweep, Standardize, and Sustain, provide a methodology for
organizing, cleaning, developing, and sustaining a productive work environment. In order to have
a smooth and efficient flow of work, every company needs a system to organize and maintain the
work areas.

This lean manufacturing method encourages workers to improve their working conditions and helps
them to learn to reduce waste, unplanned downtime, and in-process inventory.

Typically, 5S implementation would result in significant reductions in the amount of space needed
for existing operations. It also would result in the organization of tools and materials into
labeled and color coded storage locations, such as the well known painted outlines of tools on
pegboard.

Another result is the creation of kits to organize specific activities. These kits save a great
deal of time and aggravation. You no longer need to gather the same items repeatedly for frequent
tasks; they are all in one place. Brilliant!

5S is a cyclical methodology: sort, straighten, sweep, standardize, and sustain the cycle. This
results in continuous improvement. It is a never ending process that gradually improves
everything it touches.

The 5S Pillars
Sort. This focuses on identifying all unnecessary items from the workplace which are not needed
for day to day operations. These items receive a red tag and are placed in a central location for
everyone to see and decide what to do with. Many times these are useful items, but used so rarely
that they need to be discarded, given away or moved to a storage area.

It is surprising how much space can be liberated from just this one process. Vast amounts of
valuable floor space suddenly become available for more productive work.

Straighten. Once sorting has taken place, you create efficient storage methods so your items are
easy to locate and use, as well as put away. This would include labeling drawers, tool racks,
boxes, shelves, etc. You also will define areas such as storage, first-aid, shipping, etc.

As you can see, one S builds on the other steps; in fact, they are all integrated to form a whole
way of keeping a workplace orderly and efficient.

Sweep. This is sometimes referred to as shine as well. Sweep means to clean, to thoroughly remove
clutter and fix things. A daily follow-up cleaning is essential in order to sustain the new
improvements.

Everyone likes working in a clean environment, plus it often happens that damaged wires, pipes,
electrical outlets, etc. are discovered and repaired. This is also a safety feature of 5S.

It is also a good idea to establish targets before beginning your Sweep process. This helps keep
everyone focused and accountable.

Standardize. Once the first three 5S’s have been implemented, the next pillar is to standardize
the best practices in the work area. Individuals need to be assigned responsibility for each of
the first 3S aspects.

Then you can create procedure manuals, visual cues such as signs, schedule short blitzes to
maintain the first 3S procedures. This is important to prevent the procedures from breaking down and
getting dirty.

Sustain. This involves changing habits and is often the most difficult aspect of 5S
implementation…Changing entrenched behaviors can be difficult, and the tendency is often to
return to the status quo and the comfort zone of the “old way” of doing things.

Sustain focuses on defining a new status quo and standard of work place organization. Without the
performance reviews, and department tours. Organizations typically seek to reinforce 5S messages
in multiple formats until it becomes “the way things are done.”

The 5S circle is kept in motion by discipline. 5S training of everyone involved is essential to success as well, otherwise it will just be another program imposed from management. Often workers wondr what is lean manufacturing and when they see the positive results of 5S implementation, they will be much more enthusiastic.

Randy Hough

Plastic Injection Mold Maker

What is lean manufacturing

“You know Dad, I’ve been thinkin’, one is a lot more than zero!” my son, Thomas, age 5.

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What Does Lean Manufacturing 5S Mean?
By Michael Baker

There are so many businesses, especially in the manufacturing world, that are just clusters of mass unorganization. What I mean is they have way too much stuff at each work station, more than what the job actually entails. Lean manufacturing 5S is one of the simplest things you can do right away to help with this.

It is called 5S because it is made of words that all start with an S. Let’s look at each one of the individually and see what needs to be done.

Some people really like this first step. It is your chance to get a trash can and load it up. All of the things not needed for the job are removed and only the essentials are kept.

Set is the next step. This means you will need to find a place for all of the tools needed for the job. Some examples of ways to accomplish this are through the use of a peg board or by using tape to outline where items should be. This ensures you have a place for them and people can notice when they are not there.

The next step is shine. What this entails is cleaning everything. Tools and the work stations are included in this step. Also, people should be assigned the responsibility of keeping the area and the tools clean.

When you see the term Standardize, it means to ensure the same process you laid out originally is done exactly the same with everyone. This could mean new procedures, or periodic reviews of the area. But it needs to be kept up.

Lastly, and the most difficult one, is to sustain the area. You have built a good amount of momentum right now, so now is the best time to move to another area. Just be sure to hold the appointed people responsible for the cleanliness of the area accountable. This ensures you do not need to micro-manage the area, and can focus on the next area.

5S is a very good tool in a lean manufacturing effort, and can implemented in any part of a business. Just follow the simple steps above, and you can have a dramatic improvement in the cleanliness of the area and in the efficiency of the area.

Lean Manufacturing Secrets is a simple to read, yet in depth, guide on Lean Manufacturing. It also includes topics such as Kaizen, Kanbans, and 5S.

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