BMQR Certifications Private Limited

5S is a method to reduce waste and optimise productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results. 5S drives a cleaner environment and organises the workplace. It is one of the first Lean Manufacturing activities that companies implement on their Lean adoption. 5S can be much more than this if approached properly.

• Sort (Seiri)

• Set in Order (Seiton)

• Shine (Seiso)

• Standardize (Seiketsu)

• and Sustain (Shitsuke)

provide a methodology for organizing, cleaning, developing, and sustaining a productive work environment. This lean method enables operators and workers to reduce waste improve downtime.

Recently a "Sixth S" has been introduced to drive "Safety"

The first stage of 5S is removing the rubbish and clutter, it also involves cleaning and generally making the area tidy. A common area to implement 5S is in machine shops, this will involve removing broken tools and materials that have not been used for some time. By getting rid of unused items space can be made and items that are used on a regular basis can be found quicker.

A method of removing unused items is to TAG them. Areas are targeted with a "RED Tag" and dated. if the item is then not used within a defined period they are removed and disposed of.

Straighten / Arranging

Once you have cleaned the area out you need to ensure that the items left are kept in the right place. Tools should be located where they are needed and the utilization of shadow boards to store them in set locations.  Tools should be ordered in order of use, commonly used items being near to the worker, consideration should be given to reducing bending, stretching and excessive movement. Heavy items should be fitted with wheels, i.e, tool boxes and work benches.

As an example of 5S in our every day life, Compare your organization in the Kitchen to that of your garage ?

Now you have got rid of the rubbish and organized your tools, you need to maintain your new found order. The operators should be responsible for there own work area and not relying on the daily / weekly cleaners.

The area is their work environment and they should keep it clean and tidy. This is an educational program.

Systemize / Discipline

Once you have made the effort to tidy, organize and clean the work area you need to ensure your efforts and new found disciplines are not let to slip. This is the stage where all can fail, do not underestimate how difficult it can be to install and maintain 5S.

Implementing random and strict audits should be used to maintain the standards. You should praise good work and constructively highlight areas for improvement.

You have put into place the culture and systems to sustain 5S but you also need to look at continual improvements, do not stand still and look at moving forwards. If you get spills and leeks you need to identify the causes of them and rectify it. Records should be kept to identify the most common, dangerous, longest lasting issues. Consider using Pareto charts for this identification.

You must introduce the whole culture change, standards must be accepted through education and every one work to continued improvements as part of Lean Manufacturing. Kaizen techniques will often be deployed to further improve the working areas.

Click here and download the details of 5S...

Slide show of 5S