5S System (Lean manufacturing Methodology)

What is 5S?

          5S is a framework that emphasizes the use of a specific mindset and tools to create efficiency and value. It involves observing, analyzing, collaborating, and checking out waste and also involves the practice of removing waste. The 5S methodology is a useful tool to cut waste, boost efficiency, and just generally ameliorate the way everything is done within a facility.

The Origins of 5S

         5S began as part of the Toyota Production System (TPS), the manufacturing method begun by leaders at the Toyota Motor Company in the early and mid-20th century. This system, often mentioned to as Lean manufacturing within the West, aims to raise the value of products or services for customers. This is often achieved by detecting and removing waste from production processes.

What Does 5S Stand For?

    5S gets its name from the five Japanese words, Seiri, Seiton, Seiso, Seiketsu, and Shitsuke which translate in English to Sort, Set in Order, Shine, Standardize, and Sustain. These five steps will first guide you through clearing out, organizing, and cleaning a workspace, and then provide guidance for standardizing and sustaining your efforts.

    5S involves evaluating everything present in a space, eliminating what's unnecessary, organizing things logically, performing housekeeping tasks, and keeping this cycle going. Organize, clean, repeat.

Let's take a closer look at each of the parts of 5S.

Sort

    The first step in the 5S process is Sort, or “seiri”.The goal of the Sort step is to declutter and clear up space by eliminating things that don’t belong in the area. Some questions to ask during this phase include:

1. SORT

•  What is the purpose of this item? 
  

• When was this item last used?

•  How frequently is it used?

• Who uses it?

• Does it really need to be here?

    For cases when an item's value is uncertain for example, a tool hasn't been used recently, but someone thinks it might be needed in the future use the red tag method. Then, red-tagged items from all work areas are collected in a single location: a “lost and found” for tools, materials, and equipment. 

Set in Order

2. Set in Order

    The second step, Set in Order, was originally called “seiton,” which translates to “orderliness.” The goal of this step is to arrange the work area.  Each item should be easy to seek out, use, and return. .” During this phase, everyone should determine what arrangements are most logical.

1. Arrange work stations in such how that each tooling/equipment is in close proximity, in an easy-to-reach spot, and in a logical order adapted to the work performed. Place components consistent with their uses, with the frequently used components being nearest to the workplace.
2. Arrange all necessary items in order that they will be easily selected for use. Make it easy to find and pick up necessary items.
3. Assign fixed locations for items. Use clear labels, marks, or hints so that items are easy to return to the correct location and so that it is easy to spot missing items.

“A place for everything, and everything in its place.”

Shine

3. Shine

          Everyone thinks they know what housekeeping is, but it's one of the easiest things to overlook, especially when work gets busy. The Shine stage of 5S focuses on cleaning up the work area, which means sweeping, mopping, dusting, wiping down surfaces, putting tools and materials away, etc. importantly, the Shine step is not meant to be a job for the maintenance or janitorial staff. Each worker should clean their own work area and the equipment they use. This approach has several benefits:

• Workers who are familiar with the area will quickly notice any problems that arise

• Hazards or difficult situations will be understood and accounted for

• Items that are out of place or missing will be recognized

•  Workers will tend to keep their own workspaces cleaner during normal operations

being willing to pick up trash and so on. But for 5S to give the best results, each worker should take personal responsibility for their own working space.

    Everyone should pay attention to the overall cleanliness of the workplace,

     If the people keeping the area clean are the same people who work there regularly, they will be quick to recognize any of these problems.

    With the constant cleaning and inspections used in the Shine step of 5S, the system can feed into a preventative maintenance program. This way, 5S can extend the working life of the equipment and help reduce emergency downtime.

Standardize

4. Standardize

    The first three steps of 5S cover the basics of clearing, organizing, and cleaning a workspace; on their own, those steps will provide short-term benefits. The fourth step is Standardize, or “seiketsu,” which simply means standardization. By writing down what is being done, where, and by whom, you can incorporate the new practices into normal work procedures.

It’s been said that  “If it isn’t written down, it didn’t happen.”

    The aim of this step is to standardize the achievements of the first 3 steps, i.e. to roll out best practices by applying common color codes, consistent labeling, or standard working practices. All workstations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station. Standardized processes, applied across the company, enable employees to adapt quickly to any workstation and reduce training expenses significantly.

 Sustain

5. Sustain

    The fifth step of a 5S program is Sustain. The 5S approach was never meant to be a one-time event, but an ongoing cycle. This is key because early successes in 5S can open the way for problems. If open space becomes available in the Sort step, but afterward, tools and materials are allowed to gradually fill in that space without any organization, the end result can be an even bigger mess. The solution is to apply the ideas of 5S over and over, as a routine part of normal work. That’s why Sustain is so important.

"Don't slip back into old habits"

Make 5S part of daily work so it becomes a habit. Ideally, 5S becomes a part of an organization's culture. And when 5S is sustained over time, that's when businesses will start to notice continuous positive results.

This step can be difficult to achieve as it requires behavior change and ongoing motivation.

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