Overview of 5S Lean Management

5S is a systematic way of organizing workplaces by removing waste, refining flow, and decreasing the number of procedures where probable. It applies the five principles: Sort (seiri), Set in order (seiton), Shine (seiso), Standardize (seiketsu), and Sustain (shitsuke). These principles were established by Toyota Motor Company and has enhanced efficiency in their manufacturing facilities.

What Is Sort?

The Sort step separates items in workspace that need from those that do not need or may not need by moving the latter to a "red tag" holding area.

Why Need to Sort?

Sort permits to have a more productive workspace by removing unneeded clutter.

How to Implement Sort?

Separate essential items from unnecessary items. Mention sorting items into four categories:

Items required in this work area: These items are regularly use in the context of this work area and thus will stay in this work area.

Items required in another work area: Basically, these are misplaced items. If an item is used in another work area "sort" it into that area by delivering it to whomever is answerable for that work area.

Items may need: For unsure items about, use the 5S "red tag" system. Mark such items with red tags, which at a minimum should contain the name of who tagged the item, why it is thought to no longer be required, a proposed review date, and the name of the manager who must agree of disposal. Move the item to a red tag holding area, which should be organized by review month to make it easy to manage the area.

Items do not essential: These are items that are 100% confident are not required. They should be immediately discarded.

What Is Straighten?

The Straighten step carefully organizes the items that remain after sorting, such that regularly used items are easy to access and every item has a clear and easy-to-find home.

Why Need to Straighten?

Straighten allows every item to have a specific home where it can be easily found and to which it can be easily returned. It decreases the waste from excess motion as items are placed in more ergonomic locations.

How to Implement Straighten?

After sorted items, it’s time to choose how want to organize them. Mention the following methodology:

Provide easy access to regularly used items: The main to decreasing waste from excess motion is to place regularly used items within easy reach.

Group like items: Group the remaining items into logical categories and brainstorm the greatest way to organize and store each of these categories.

Visualize item homes: For each group, choose on the best way to make it clear when an item is missing.

Use containers: If it is suitable for the type of item, consider organizing it within a container.

Unleash the labeler: If an item is too big to put into a container, consider giving it a frame and putting a label on the item in addition to the frame.

Be agile: initial straighten pass will likely deliver an improvement - but also likely to overlook some probable developments. Meet with team after one week and again after two weeks to brainstorm further improvements as part of initial implementation.

What Is Shine?

The Shine step elevates the work area by carefully cleaning and inspecting tools, equipment, and other items. It also can contain routine maintenance on equipment, which is one of the ways it flows directly into TPM.

Why Need to Shine?

Shine makes a work environment that occupies and empowers operators by giving them more responsibility and agency over their work area. It also helps them to classify problems before they interfere with production.

How to Implement Shine?

After straightened items, it’s time to elevate the work area by cleaning, inspecting, and in some cases performing routine maintenance. Mention the following:

Grab the metaphorical spray bottle: Using suitable cleaners and cleaning tools, make the work area sparkle. With every sweep, mop, brush, wipe, wash, and wax, strive to return workspace to its former glory.

Find the source: The guiding principle of this step is "clean to understand". If there are any signs of leaks, spills, strive to understand the source. It is likely an early warning of a future problem.

Inspect: After cleaning each item, take a moment to look it over and inspect its condition.

What Is Standardize?

The Standardize step is a bridge between the first three steps. In this step goal is to capture best practices for 5S as standardized work for team.

Why Need to Standardize?

Standardize makes 5S repeatable. It transforms 5S from a one-off project to a reproducible set of activities.

How to Implement Standardize?

It’s time to assure all hard work remains to pay dividends into the future. Set expectations for the future with a documented 5S procedure. To do so, mention that:

Document in pairs: Have one team member walk through each task as another documents it to confirm nothing important is missed.

Capture the essence: huge proponents of simplicity. Capture the essence of each task and no more. Otherwise, documentation will very likely not be maintained.

Prefer checklists: Checklists feel easy. Short checklists feel even easier. A great format is to have a name for each task that serves as a fast reminder.

Organize to simplify: Organize checklists by role, by shift, and by frequency. This will make the 5S process much less intimidating to team.

What Is Sustain?

The Sustain step assures that 5S is useful on an ongoing basis. It transforms standardized 5S processes into regularly completed tasks.

Why Need to Sustain?

Iterative 5S processes lock in gains and confirm further and constant progress.

How to Implement Sustain?

Once standardized, it’s time to constantly act upon those standards.

Create a schedule: Embed 5S practices as scheduled tasks.

Teach through demonstration: Instruct employees on how to conduct 5S tasks through demonstration and training. Showing employees what is expected of them will prepare them to enact tasks on their own.

Supervise to solo: After initial 5S lean management training for employees, gently supervise while they remain to form habits. It is easy to make mistakes, so patiently and helpfully offer corrections when essential.

Adapt as necessary: When receiving feedback on tasks, see where changes can be made to make the tasks easier and more effective. Standardized work is proposed to be living documentation.