What is 5S Methodology? | 5S System | 5S Principles | PDF

 What is 5S in the Workplace?

➝ 5S is a system for organizing spaces so work can be performed efficiently & effectively safely it is a fundamental tool of Lean Manufacturing.

→ It is a system for organizing space so work can be performed efficiently & effectively and safely.

→ Sometimes it is also referred to as a good housekeeping practice but both are different things.

➝ 5S Methodology was developed in Japan.

Table of Contents:

• What is 5S in the Workplace?
• History of 5S
• Objectives of 5S System
• 5S Meaning | What does the 5S stand for?
• Steps for 5S Implementation
• Step-01: Implementation of Seiri or Sort
• Step-02: Implementation of Seiton or Set In Order
• Step-03: Implementation of Seiso or Shine (cleaning)
• Step-04: Implementation of Seiketsu or Standardize
• Step-05: Implementation of Shitsuke or Sustain
• Top Management's Support Needed for Sustain 5S
• Benefits of 5S Implementation
• Conclusion

History of 5S:

→ 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 Ongoing Improvement) before the development of this Methodology.

Objectives of 5S System:

⏩ The main objectives of 5S System are mentioned below:

→ Improve safety

→ Remove waste from the workplace

→ Increase product and service quality

→ Provide the environment for continuous improvement

→ Make abnormalities immediately visible

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

→ It stands for five Japanese words Seiri, 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 → Standardize or Standardization

→ (5S) Shitsuke → Sustain or Discipline

Steps for 5S Implementation:

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

⏩ Refer to the below-mentioned basic points for preparation of 5S Implementation:

→  Team formation

→  Gemba walk executing

→  Zone-wise area distribution with area leader

⏩ Refer to the below-mentioned 5 Steps of the 5S Methodology:

1. (1S) Seiri → Sort or Tidiness
2. (2S) Seiton → Set In Order or Orderliness
3. (3S) Seiso → Shine (Clean) or Cleanliness
4. (4S) Seiketsu → Standardize or Standardization
5. (5S) Shitsuke → Sustain or Discipline

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Step-01: Implementation of 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 unnecessary items or materials from a workspace.

→ Keep only what is actually required every day from the workspace.

→ Materials, equipment, instruments, or any things that are not frequently used should be moved to a separate, common storage area called Red Tag Zone.

→  Items that are not used should be removed or recycled.

→ Please do not keep anything in your workplace just because it might be used in the future.

→ The whole team should spend a few hours going through the entire area (inside cabinets, under and behind machines. Everywhere !!!)

→ All obvious scrap should be put in the scrap area / Bin

→ All unidentified things should be put in the “Red tag”/ quarantine area.

→ Only items that are required should remain.

5 Steps for Sorting:

1. Cleaning
2. Classifying
3. Assign Responsibility
4. Red Tagging of unnecessary things
5. Recycling or Reassignment of things arrived in the Red Tag Zone.

→ For better understanding show the below picture of the Before-After comparison of Work Place and the Red Tag.

Step-02: Implementation of Seiton or Set In Order:

→ Set in order is for organizing the items or materials at the workplace.     

→ “Define Place for Everything and Put Everything in its place”

→ We can use an organized workplace more efficiently and effectively

→ To arrange all necessary items for the economy of movement.

→ Put things as per the frequency of use.

→ Provide safe storage – heavy items at a low level, and light items at a height.

→ If any item is missing then we can easily find out it

⏩ Basic Principles of Set in Order:

→ The items that are used very frequently should be kept nearer to where they are used.

→ Items that are used very few times should be kept far compared to frequently used things.

→ After completion of work keep things in their defined place.

→ If several things are used together, then store them together.

→ For example, if a welding rod is used with a welding machine then both should be kept together.

→ Store things in a place where people can easily find it.

→ Identify all items (including fixtures, gauges, tools, jigs, molds, etc.) and mark identification symbols on them so we can easily identify and return them to their identified storage location.

→ For better understanding refer to the below picture of the sort in order.

Step-03: Implementation of Seiso or Shine (cleaning):

→ After Sort and Set In Order, the workplace requires regular cleaning.

→ Shine is used for regular cleaning of the workplace, tools, and equipment     

→ Cleanliness makes defects easier to detect.

→ Better customer satisfaction

→ Aids efficiency and reduces accidents

→ Creates a better working environment

→ It is not just the job of a housekeeper, it is everyone's responsibility

→ Every workplace should have a person, or group, assigned to clean that area.

→ The best approach is that those who work in a workplace are also responsible for cleaning that area.

⏩ Cleaning Process:

→ Define and document

→ Decide Who, What, When, Where, How, etc…

→ Who is responsible for cleaning

→ What needs to be cleared and where

→ When it will be done

→ How is it to be done and which tools require

→ For better clarity refer to the below picture in which we can easily see the comparison of the workplace before and after cleaning.

Step-04: Implementation of Seiketsu or Standardize:

→ After completion of Shine or Clean, Standardize will come.

→ Standardizing means documenting all necessary processes or activities.

→ In Standardize we 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 will help them to remember the new standards and it encourages them to do the same.

→ We can use labels, symbols, posters, and banners for standardization.

⏩ (A) How do we Standardise?

→ Document standard ways of working (SOPs), Process Flow Diagram or Flow Chart

→ Standardize labeling, 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 methods to show where the work enters and leaves the cell.

→ Standard methods for identifying components and tool locations

Step-05: Implementation of Shitsuke or Sustain:

→ Sustain needs to maintain 5S within the factory 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”.

⏩ (A) 5S Audit:

→ Independent audit of an area

→ Capture current state – Use color photographs

→ Create simple audit sheets – with a score

→ Conduct audits

Top Management's Support Needed for Sustain 5S:

→ We can sustain commitment towards 5S methodology in our industry with the help of Top management's support.

⏩ Top Management should be involved in these activities such as:

→ Conducting inspections on a random basis to check the sustenance of the system

→ Establish a proper communication channel from top to bottom and bottom to top.

→ Provide training to employees.

→ Participation in promotional events at the factory.

Benefits of 5S Implementation:

• Increase productivity through effectiveness
• Reduction in delays
• Improved Quality
• Improve Safety
• Set-up times reduced
• Morale & Motivation Increase
• Less stress for operators
• Safer work environment
• Improvement in the regular process

Conclusion:

→ The 5S Methodology is a systematic approach for organizing and standardizing the workplace including safety.

→ This method focuses on improving efficiency, safety, and productivity.

→ This framework involves five key steps and it provides a robust framework for transforming workplace environments into organized, efficient, and safe spaces.

→ By systematically implementing the five steps we can improve performance.

→ By implementing the 5S Method we can get tangible such as reduced waste, increased efficiency, etc, and intangible benefits such as employee morale, motivation, culture of continuous improvement, etc.

→ The 5S Method is not only a method but it is also a tool for long-term success and operational excellence.