5S in the Workplace | 5S Implementation – Greendot Management Solutions

Greendot Management Solutions > Blogs > Lean Management > 5s > 5S in the Workplace | 5S Implementation

What’s 5S in the Work Place?

5S Methodology was developed in Japan and it’s a system for organizing spaces so work can be performed efficiently & effectively safely and it’s a fundamental tool of Lean Manufacturing
It’s a system for organizing space so work can be performed efficiently & effectively with safely.
Now and then it’s also referred to as a good housekeeping practice but both are different things

History:
Benefits of 5S
Quality
5S Meaning| What does the 5S stand for?
5S Implementation

1. History:

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 On going Improvement) before the development of this Methodology.

3. Benefits of 5S

Increase productivity through effectiveness
Reduction in delays
Improved

3. Quality

Improve in Safety
Set-up times reduced
Morale & MotivationIncrease
Lessstress for operators
Safer work atmosphere
Improvement in the regular process

4. 5S Meaning| What does the 5S stand for?

It stands for five Japanese wordsSeiri, Seiton, Seiso, Seiketsu, and Shitsuke.
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 → Standardizeor Standardization
(5S) Shitsuke → Sustain or Discipline

Also, refer to What Is 5s In Hindi ▶ What Is 5s Methodology Solution

5. 5S Implementation

Now we will see the implementation of 5S step by step.

(1) 1S-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 nonessential items or materials from a workspace.
Keep only what’s actually needed every day from the workspace.
Materials, equipment, instruments, or any things that aren’t constantly- used should be moved to a separate, common warehouse area called Red Tag Zone.
Items that aren’t used should be removed or recycled.
Please don’t keep anything in your plant just because it might be used in the future.
The whole team should spend a few hours going through the entire area (inside closets, under and behind machines. Everyplace!!!)
All obvious scrap should be put in the scrap area/ box
All unidentified things should be put in the “ Red label”/ quarantine area.
Only items that are needed should remain.

Also, refer Top 10 Resistance For 5s Implementation 🏻 New 5s Implementation (video) Guidelines Popular Video

Steps for Sorting

Cleaning
Classifying
AssignResponsibility
Red Tagging of nonessential things
Recycling or Reassignment of things arrived in Red Tag Zone.

For a better understanding how the below picture of the Before-After comparison of Work Place and Red Tag

5S Exemplifications

(2) 2S-Seiton or Set In Order

Set in order is for organizing the items or materials at the plant.
“ DefinePlace for Everything and Put Everything in its place”
We can use an systematized plant more efficiently and effectively
To arrange all necessary items for the economy of movement.
Put things as per the frequency of use.
Provide safe warehouse – heavy items at a low rank, light items at a height.
If any item is missing also we can fluently find out it

Basic Principles of Set in Order

The items that are used really constantly should be kept nearer to where they’re used.
Items that are used really multiple times should be kept far compare to constantly used things.
After completion of work keep things in their defined place.
If several things are used together, also store them together.
For illustration, a welding rod is used with a welding machine also both should be kept together.
Store things in a place where people can fluently find
Identify all items ( including fixtures, gauges, tools, jigs, molds, etc.) and mark identification symbols on them so we can fluently identify and return them to their identified warehouse place.
For better understanding refer to the below picture of the sort in order.

2s Set in Order

5S Housekeeping

(3) 3S-Seiso or Shine (cleaning)

After Sort and Set In Order, the plant requires regular
Shine is used for regular cleaning of the plant, tools, and equipment
Cleanliness makes defects easier to detect.
Better client satisfaction
Aids efficiency and reduces accidents
Creates a better working atmosphere
It isn’t just the job of a housekeeper, it’s everyone’s responsibility
Every plant should have a person, or group, assigned to clean that area.
The best approach is that those who work in a plant are also responsible for cleaning that area.

(A) Cleaning is an ongoing process

Define and document
Decide Who, What, When, Where, How, etc …
Who’s responsible for cleaning
What needs to be cleared and where
When it’ll bedone
How is it to be done and which tools demand
For better clarity related to the below picture in which we can fluently see the comparison of the plant before and after cleaning.

3s Shine

4S-Seiketsu or Standardize

After completion of Shine or Clean, Standardize will come.
Standardizing means documenting each necessary process or activity.
In Standardizewe 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’ll help them to remember the new standards and it encourages them to do the same.
We can use tags, symbols, posters, and banners for standardization.

(A) How do we Standardise?

Document standard ways of working ( SOPs),. Process Flow Diagram or Flow Chart
Standardizelabelling, 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 methodologies to show where the work enters and leaves the cell.
Standard methodologies for identifying components and tool places

(D) 5S Audit

Independent audit of an area
Capture current state – Use color photos
Produce simple audit sheets – with a score
Conduct audits

4s Standardize

(5) 5S-Shitsuke or Sustain

Sustain needs to maintain 5S within the plant 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”.

you can also avial 5s Training from us

5s Sustain

Top Management’s Support needed for Sustain

We can sustain our commitment to the 5S methodology in our industry with the help of Top management’s support.
Top Management should be involved in these activities similar as
Conducting inspections on a random basis for checking the sustenance of the system
Establish a proper communication channel from top to bottom and bottom to top.
Provides training to workers.
Participation in promotional events at the plant.