What is 5S in the Workplace?
➝ 5S is a system for organizing spaces so work can be performed efficiently & effectively safely it is a fundamental tool of Lean Manufacturing.
→ It is a system for organizing space so work can be performed efficiently & effectively and safely.
→ Sometimes it is also referred to as a good housekeeping practice but both are different things.
➝ 5S Methodology was developed in Japan.
Table of Contents:
- What is 5S in the Workplace?
- History of 5S
- Objectives of 5S System
- 5S Meaning | What does the 5S stand for?
- Steps for 5S Implementation
- Step-01: Implementation of Seiri or Sort
- Step-02: Implementation of Seiton or Set In Order
- Step-03: Implementation of Seiso or Shine (cleaning)
- Step-04: Implementation of Seiketsu or Standardize
- Step-05: Implementation of sh*tsuke or Sustain
- Top Management's Support Needed for Sustain 5S
- Benefits of 5S Implementation
History of 5S:
→ This methodology was developed in Japan by two gentlemen, Osada, and Hirano who structured a framework for implementing their philosophy.
→ Some say that the principles of this Methodology came from Henry Ford.
→ Henry Ford used the CANDO system (CANDO stands for Cleaning up, Arranging, Neatness, Discipline, and Ongoing Improvement) before the development of this Methodology.
Objectives of 5S System:
⏩ The main objectives of 5S System are mentioned below:
→ Improve safety
→ Remove waste from the workplace
→ Increase product and service quality
→ Provide the environment for continuous improvement
→ Make abnormalities immediately visible
5S Meaning | What does the 5S stand for?
→ It stands for five Japanese words Seiri, Seiton, Seiso, Seiketsu, and sh*tsuke.
→ English Meaning of the above Japanese words are :
→ (1S) Seiri → Sort or Tidiness
→ (2S) Seiton → Set In Order or Orderliness
→ (3S) Seiso → Shine (Clean) or Cleanliness
→ (4S) Seiketsu → Standardize or Standardization
→ (5S) sh*tsuke → Sustain or Discipline
Steps for 5S Implementation:
→ Now we will see the implementation of 5S step by step.
⏩ Refer to the below-mentioned basic points for preparation of 5S Implementation:
→ Team formation
→ Gemba walk executing
→ Zone-wise area distribution with area leader
⏩ Refer to the below-mentioned 5 Steps of the 5S Methodology.
- (1S) Seiri → Sort or Tidiness
- (2S) Seiton → Set In Order or Orderliness
- (3S) Seiso → Shine (Clean) or Cleanliness
- (4S) Seiketsu → Standardize or Standardization
- (5S) sh*tsuke → Sustain or Discipline
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Step-01: Implementation of Seiri or Sort:
→ The first step is to Sort in this Methodology.
→ "Sorting" means to sort everything in each work area that we need and what we do not need?
→ Sort means removing unnecessary items or materials from a workspace.
→ Keep only what is actually required every day from the workspace.
→ Materials, equipment, instruments, or any things that are not frequently used should be moved to a separate, common storage area called Red Tag Zone.
→ Items that are not used should be removed or recycled.
→ Please do not keep anything in your workplace just because it might be used in the future.
→ The whole team should spend a few hours going through the entire area (inside cabinets, under and behind machines. Everywhere !!!)
→ All obvious scrap should be put in the scrap area / Bin
→ All unidentified things should be put in the “Red tag”/ quarantine area.
→ Only items that are required should remain.
5 Steps for Sorting:
- Cleaning
- Classifying
- Assign Responsibility
- Red Tagging of unnecessary things
- Recycling or Reassignment of things arrived in the Red Tag Zone.
→ For better understanding show the below picture of the Before-After comparison of Work Place and the Red Tag
Step-02: Implementation of Seiton or Set In Order:
→ Set in order is for organizing the items or materials at the workplace.
→ “Define Place for Everything and Put Everything in its place”
→ We can use an organized workplace more efficiently and effectively
→ To arrange all necessary items for the economy of movement.
→ Put things as per the frequency of use.
→ Provide safe storage – heavy items at a low level, and light items at a height.
→ If any item is missing then we can easily find out it
⏩ Basic Principles of Set in Order:
→ The items that are used very frequently should be kept nearer to where they are used.
→ Items that are used very few times should be kept far compared to frequently used things.
→ After completion of work keep things in their defined place.
→ If several things are used together, then store them together.
→ For example, if a welding rod is used with a welding machine then both should be kept together.
→ Store things in a place where people can easily find it.
→ Identify all items (including fixtures, gauges, tools, jigs, molds, etc.) and mark identification symbols on them so we can easily identify and return them to their identified storage location.
→ For better understanding refer to the below picture of the sort in order.
Step-03: Implementation of Seiso or Shine (cleaning):
→ After Sort and Set In Order, the workplace requires regular cleaning.
→ Shine is used for regular cleaning of the workplace, tools, and equipment
→ Cleanliness makes defects easier to detect.
→ Better customer satisfaction
→ Aids efficiency and reduces accidents
→ Creates a better working environment
→ It is not just the job of a housekeeper, it is everyone's responsibility
→ Every workplace should have a person, or group, assigned to clean that area.
→ The best approach is that those who work in a workplace are also responsible for cleaning that area.
⏩ Cleaning Process:
→ Define and document
→ Decide Who, What, When, Where, How, etc…
→ Who is responsible for cleaning
→ What needs to be cleared and where
→ When it will be done
→ How is it to be done and which tools require
→ For better clarity refer to the below picture in which we can easily see the comparison of the workplace before and after cleaning.
Step-04: Implementation of Seiketsu or Standardize:
→ After completion of Shine or Clean, Standardize will come.
→ Standardizing means documenting all necessary processes or activities.
→ In Standardize we can turn Good Practices into Good Habits.
→ By developing standards for process, all person knows what to do, how to do it, when to do it, where to do it, etc..
→ Give awareness about standardizing to all persons.
→ It will help them to remember the new standards and it encourages them to do the same.
→ We can use labels, symbols, posters, and banners for standardization.
⏩ (A) How do we Standardise?
→ Document standard ways of working (SOPs), Process Flow Diagram or Flow Chart
→ Standardize labeling, signage, and Flow
→ Audits
⏩ (B) Standard Work:
→ Document the current agreed way of doing a process
→ Provides a baseline for improvement
→ Reduces variation between people/shifts
⏩ (C) Standardized flow and Signage:
→ Common methods to show where the work enters and leaves the cell.
→ Standard methods for identifying components and tool locations
Step-05: Implementation of sh*tsuke or Sustain:
→ Sustain needs to maintain 5S within the factory or work pace.
→ Keep a record of progress with evaluations, communication, and training-related activity.
→ Assign continuing responsibility.
→ Sustain keeps watch on ongoing training activity and maintains the established System.
→ Maintaining Audits
→ Maintaining cleaning
→ Making it “A Way of Life”.
⏩ (D) 5S Audit:
→ Independent audit of an area
→ Capture current state – Use color photographs
→ Create simple audit sheets – with a score
→ Conduct audits
Top Management's Support Needed for Sustain 5S:
→ We can sustain commitment towards 5S methodology in our industry with the help of Top management's support.
⏩ Top Management should be involved in these activities such as:
→ Conducting inspections on a random basis to check the sustenance of the system
→ Establish a proper communication channel from top to bottom and bottom to top.
→ Provide training to employees.
→ Participation in promotional events at the factory.
Benefits of 5S Implementation:
→ Increase productivity through effectiveness
→ Reduction in delays
→ Improved Quality
→ Improve Safety
→ Set-up times reduced
→ Morale & Motivation Increase
→ Less stress for operators
→ Safer work environment
→ Improvement in the regular process
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