5S – Workplace Organisation…. And Much More!
5S is in place in ALL world class organisations, it aims to:
- Remove waste from the workplace.
- Provide reduction in non value added activities.
- Provide an environment where continuous improvement is embraced.
- Improve safety.
- Increase quality.
Step 1 (Seiri) Sort
- Clearout and Classify
- what you KNOW you definitely need all the time.
- what you KNOW you definitely need occasionally.
- what you THINK you might need in the future.
- what you THINK you no longer need.
- Never Assume. Ensure that everyone is in agreement.
- Check to make sure that what you think becomes what you KNOW.
- Remember! Redundant items cost money to store – If you don’t need it don’t keep it!
Step 2 (Seiton) Set in Order
- Put Everything in its correct place
- Organise storage for all equipment i.e. what, where, how many.
- Frequency of use defines location relative to point of use.
- If its used frequently keep it close / low frequency store offline.
- Shop organisation must have clear walkways, work areas, rest areas. etc.
- Consider using different coloured floor areas to highlight walkways, work, storage areas etc.
- All essentials such as fire extinguishers and safety equipment must be visible and easily accessible.
The place must be
- Appropriate to usage
- Well maintained
- Tools Easily located
- Tools / locations Clearly identified
A place for everything and everything in its place
Step 3 (Seiso) Shine
Clean and Check
- Regular cleaning schedules are required
- Create a clean and tidy working environment and maintain it.
- Define responsibility zones for cleaning areas, and clarify roles and responsibilities.
- Develop regular routines for maintaining a clean environment (e.g.. 5 min 5 S etc).
Cleaning must become an activity which is:
- A source of pride
- Seen as a value added contribution
Cleanliness is the basis of quality. Once the workplace is clean it must be maintained, creating a spotless workplace.
Step 4 (Seiketsu) Standardise
- Good Housekeeping
- Decide what is classed as an abnormality and make it visible to the operator.
- Design clear, standard labels for locations, tools, machine conditions and locate them in standard positions.
- Provide indicators where limits can be exceeded.
- Draw position markers in places where items are removed and returned.
Agree and set :
- Standards of cleanliness.
- Procedures for maintaining standards.
- Standard marking and labelling of all items.
- Standard methods for indicating limits, identifying locations, etc.
The system must be controlled and maintained.
Step 5 (Shitsuke) Sustain
Custom and Practice
- Adhere to the system rules
- Develop and maintain habits through training and discipline. (At all times)
- Use visual rather than verbal communication to train for new procedures.
- Involve everyone in the development of standard documentation.(e.g.. Checksheets etc.)
- Be conscious of time (3-10min).
- It is important to maintain discipline
- Incorrect practices must be identified.
- Correct practices have to be taught and demonstrated.
- Ensure everyone’s understanding and agreement.
Without training and discipline the other steps will fail