What
Is 5S?
5S
is a procedure that organizes individual workstations
or departments. The objective of 5S is to increase efficiency at the
micro-level by keeping the workplace neat,
orderly and accessible.
The results are visually dramatic and also increase pride and morale.
Visual
Control uses visual (and other sensory devices) to guide everyday
decisions such as "When should I cross this street?."
Conceptually, Visual Control is not the same as 5S but the two ideas
are closely linked and often used together.
There
are many variations of 5S, mostly of minor
importance-- for example,
different translations of the original Japanese. The extent of
the organization effort also varies. Some versions are little more
than a cleanup while others involve time and motion studies or
layout. Safety is often included as a step to eliminate
unsafe conditions and enhances awareness.
What
Does 5S Accomplish?
5S
improves efficiency at the micro-level. It can eliminate searching
for tools, for example. It may eliminate wasted steps or
long
reaches that are ergonomically hazardous. Since workers themselves
analyze and rearrange their own workplace, it forces each worker to
think about their activities. It develops the "Kaizen Mind."
For more on the possible range of improvements in safety,
absenteeism, productivity, space and wasted motion, see The
Payoff from 5S.
The
Elements of 5S
The
table below summarizes the five elements. Most elements are
straightforward and self explanatory. The
five words are a convenient mnemonic device. They derive from
equivalent Japanese words which also started with an “S”. Each,
however, involves much more than the word alone implies. Click
on each word for more detail.
| 1 |
Sort |
Sort through and sort out junk,
seldom-used items and necessary items. |
| 2 |
Shine |
Clean and paint
and clean regularly. |
| 3 |
Set |
Set locations; use boundaries
& addresses to assure recoil. |
| 4 |
Standardize |
Define and
standardize work processes, 5S activities and tasks. |
| 5 |
Sustain |
Make 5S a way of
life, institutionalized in the organization. |
(Click
on above titles for more information)
When
To Implement 5S
This
is a point for debate. Many
firms start their Lean Journey with 5S. Setting implementation priorities involves many factors. It may be best
to start with an element having faster and more verifiable
savings.
The
other side argues that, initially, 5S can
be relatively easy to implement and has direct benefits.
Moreover, it establishes a standard of
discipline that begins the cultural
change necessary for other elements of Lean
Manufacturing. Ultimately,
there are many paths to Lean and it is probably more important to just
start then it is
to find the "correct" path. |
