5S

Based on Japanese words that begin with the letter "S", the 5S philosophy focuses on a system of practices used to create a workplace suited for visual control and lean production. 5S simplifies the work environment, produces effective work place organization and standardized work procedures, reduces waste and non-value activity while improving quality, efficiency and safety.

Principles of 5S

Sort: (Seiri) the first "S" focuses on eliminating unnecessary items from the workplace. Sorting keeps necessary work items in the work area. Infrequently used items are moved to an organized storage location outside of the work area, while unneeded items are discarded.

Seiri fights the habit to keep things because they may be useful someday. Seiri helps to keep the work area neat and organized. Seiri is also an excellent way to gain valuable floor space and eliminate old broken tools, obsolete jigs and fixtures, scrap, and excess raw material. The Sort process also helps prevent the "just-in-case" job mindset.

Set In Order: (Seiton) is the second "S" and focuses on efficient and effective storage methods.

You must ask these questions:

1. What do I need to do my job?
2. Where should I locate this item?
3. How many of this item do I really need?

Strategies for effective Set In Order are: painting floors, outlining work areas and locations, shadow boards, and modular shelving and cabinets for needed items such as trash cans, brooms, mops and buckets. "A place for everything and everything in its place."

Shine: (Seiso) Once the clutter and unnecessary items have been eliminated, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutter-free work area and the Shine step helps to create ownership in the equipment and facility.

Standardize: (Seiketsu) Once the first three S's have been implemented, the next step is to concentrate on standardizing "best practice" in the work area. Employees should participate in the development of such standards - they are a valuable but often overlooked source of information regarding their work.

Sustain: (Shitsuke) This is by far the most difficult "S" to implement and achieve. Human nature is to resist change. More than a few organizations have found themselves with a dirty, cluttered shop a few months following their 5S implementation. The tendency is 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.

Once fully implemented, the 5S process can increase morale, create positive impressions on customers, and increase efficiency and organization.

The 5S Visual Workplace pays for itself in the time and money saved hunting for necessary supplies, tools, and equipment. The 5S system will give benefits that are quickly visible in the workspace and the bottom line.

5S Produces Visible Results

• Increases productivity
• Reduces lead times
• Reduces waste in materials, space and time
• Reduces changeover time
• Improves safety

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