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5S
Sort
Straighten
Shine
Standardise
Sustain
5S provides a methodology for organising, 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"
5S Sort / Cleanup
The first stage is removing the rubbish and clutter, it also involves cleaning and generally making the area tidy. A common area to implement 5 S 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.
5S 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 utilisation 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 organisation in the Kitchen to that of your garage ?
5S Shine / Neatness
Now you have got rid of the rubbish and organised your tools, you need to maintain your new found order. The operators should be responsible for their 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.
5S Standardise / Discipline
Once you have made the effort to tidy, organise 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. Continued training at this stage is essential
Implementing random and strict 5S audits should be used to maintain the standards. You should praise good work and constructively highlight areas for improvement.
Five S Sustain / Ongoing 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.