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

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. 

References for images:
http://5sbestpractices.ning.com/photo/5s-shine-station?context=userhttp://www.niftysol.com/tag/5s/
http://www.businessbankoftexas.com/5s-and-visual-controls-my-processes-are-talking-back.htm
http://www.labelprinter.com/5s/identification-labels.php
http://www.niftysol.com/category/blog/5s/
http://www.slideshare.net/niteshjoshi/204-housekeeping-checklist
http://www.tocforme.com/toc/atoolrack.html