THE 5S METHODOLOGY

This is one of the process improvement tools that makes it possible to simplify processes, making them more agile, clean and oriented towards productivity and optimization of space and the elements that compose it.

This methodology is originally from Japan and each one of the “S” has its correspondence in the Japanese language as briefly explained below.

Benefits of implementing 5S

• Increased Productivity: Every organization works towards achieving increased productivity, after all, productivity increases the overall return on investment. According to global research it has been found that effective implementation of 5S & lean manufacturing resources provides this improvement.
• Improved Safety: Improved safety is yet another benefit of 5S implementation. A clean workplace environment, especially in a manufacturing unit can result in significant reduction in the number of injuries sustained by workers. Most often, unattended chemical spills increases the chances of slips and falls.
• Reduction in Waste: Implementing 5S will also yield a fair reduction in lost and damaged items in the workplace. A clear and organized workplace with proper labeling provides workers the flexibility to replace damaged items in the designated places, thereby minimizing the total number of misplaced and lost tools and equipment. Further, the appropriate management of equipment also minimizes damages that are generally caused to various parts of the products during the production process.
• Worker Commitment: Achieving worker commitment is one of the major goals of implementing 5S lean manufacturing training.This is because the workers would be largely responsible for using it on the ground. 5S emphasizes on worker participation by streamlining their work and allowing them to provide inputs to make productive changes in the overall design of the workplace and also to carry out its maintenance tasks.

Hassle-free 5S Implementation with PSQC

The simple and practical 5S implementation methodology brings change in mind-set and enhanced accountability at the all the levels especially at the workmen level at the shop floor. 5S implementation needs systematic and practical approach with an objective of developing 5S culture throughout the organization. There are 5 phases in 5S technique as mentioned below:

• Sort
  • Make work easier by eliminating obstacles
  • Reduce chances of being disturbed with unnecessary items
  • Evaluate necessary items with regard to cost or other factors
  • Remove all parts or tools that are not in use
  • Segregate unwanted material from the workplace
  • Define Red-Tag area to place unnecessary items that cannot immediately be disposed of
  • Need a fully skilled supervisor for checking on a regular basis
  • Waste removal
  • Make clear all working floor except using material
  • Sort bad and good things
  • Sort all items as per their parts
• Set in Order
  • Arrange all necessary items so that they can be easily selected for use
  • Prevent loss and waste of time by arranging workstation in such a way that all tooling/equipment is in proximity
  • Make it easy to find and pick up necessary items
  • Ensure a first-in-first-out FIFO basis
  • Make workflow smooth and easy
  • All the above work should be done on a regular basis
  • Place components according to their uses, with the frequently used components being nearest to the workplace
• Shine
  • Arrange all necessary items so that they can be easily selected for use
  • Prevent loss and waste of time by arranging workstation in such a way that all tooling/equipment is in proximity
  • Make it easy to find and pick up necessary items
  • Ensure a first-in-first-out FIFO basis
  • Make workflow smooth and easy
  • All the above work should be done on a regular basis
  • Place components according to their uses, with the frequently used components being nearest to the workplace
• Standardize
  • Standardize the best practices in the work area
  • Maintain high standards in workplace organization at all times
  • Everything in its right place
  • Every process has a standard
  • Standardize color coding of usable items
  • People know the process of that specific job
• Sustain
  • Not harmful to anyone
  • Also translates as “do without being told”
  • Perform regular audits
  • Training and discipline
  • Training is a goal-oriented process
  • Self-discipline
  • To maintain proper order
  • Ensure all defined standards are being implemented and heard
  • Follow the process, but also be open to improvement