Monday, November 25, 2013

Steps Necessary to Successfully Implement 5S


Have you ever been inside a manufacturing facility, warehouse, or distribution center?
Was it dirty and cluttered?

If so, this blog will instruct you how to implement a system called 5S in your workplace..

This blog is intended for employees who are new to the concept of 5S.

Introduction
  • 5S is a company culture and philosophy.
  • It helps aid in workplace organization.
  • Proper implication of 5S principles can lead to:
    • Cleaner workplace environment
    • Lower a company's operating costs
    • Improve safety
    • Increase employee productivity
    • Increase a company's overall employee satisfaction
  • There are five pillars of 5S: Sort, Set, Shine, Straighten, and Sustain. 
  • These five pillars have to work together to create a desired organized and productive workplace.
  • Each pillar has a main goal, as well as tools and technique on how to properly implement.
5S can be accomplished in five basic steps.


Image 1.1- The five pillars of 5S.
Step One - Sort
  • Eliminate items in the workplace that are unneeded for daily production and create a space free of clutter.
  • This will eliminate issues, such as extra tools and materials impeding workflow or time wasted spent looking for tools and materials.
  • There are many techniques that can be taken to "sort" properly. 
  • One way to sort is to red tag items when you see something that needs to be removed from a specific location. This will inform everyone that the purpose of this item needs to be evaluated.
Image 1.2: Red Tag Holding Area
 Step Two-Set
  • Create a specific location for easy storage and retrieval of materials and tools.
  • TIP: If items are used together, store together, clearly mark so everyone can locate, more frequently used tools in more easily accessible.
  • There are many techniques to "set" properly.
  • Two simple strategies to implement:
    • Label and Sign. Stick labels where you want specific items to go.
    • Tool Outline: Outline the specific area a tool goes to aid in replacement and proper location of tools.
Image 1.3: Tool Outline

Image 1.4: Label and Sign 
Step Three- Shine
  • It will include and it is not limited to the following: inspecting, cleaning, maintaining, lubricating, tightening bolts, checking fluid levels on equipment, and much more. 
  • Main focus on workstations, equipment, and materials staying clean and properly functioning on a daily basis.
  • Can lead to:
    • Higher productivity
    • Higher employee morale
    • Fewer employee injuries
5S Shine station
Image 1.5: Cleaning station 
Step Four - Standardize
  • Focuses on ensuring the first three principles (Set, Sort, Shine) are executed properly on a daily basis
  • Can be ensured by implementing visual aids or employee evaluations.
  • If executed improperly, employees will be doing tasks differently, which could lead to missing items or misuse of tools
  • If executed properly, employees will be executing principles of 5-S without even realizing.
Image 1.6: 5S Checklist
Step Five - Sustain 
  • Sustaining the five principles is crucial for long-term success.
  • Ways to "sustain":
    • Assign specific time intervals of the day to complete tasks
    • Involve management
    • Create a reward system
Summary

  • 5S is a long term process and is not a short term fix for an organization.
  • If executed properly, employees will be executing the principles of 5S without even realizing. 
  • Diligence is key to long term success for a workplace environment implementing 5S.
  • 5S will provide a solid foundation for achieving operational excellence.