What are the benefits of implementing 5S in lean manufacturing? Is it true that 5S implementation can improve production efficiency? Many people who mistakenly know 5S only give advantage to housekeeping, but actually more benefits than that.
As we know, 5S is a term for the working environment setting method. 5S was first introduced by Japan where 5S itself consists of seiri, seiso, seiketsu, and shitsuke. 5S is an approach in regulating the working environment, which essentially seeks to eliminate waste so as to create an effective, efficient, and productive work environment.
How to apply 5s at workplace?
1. Seiri (Sort)
– Separating important and unimportant items, so we only store the necessary items and get rid of the useless ones.
– Put red tags on unneeded, damaged, and / or unnecessary items or documents.
– Collect goods or documents required by type.
– Disposing of items or documents that are unnecessary or unused during the past year.
– If the goods or documents are used only once every 6-12 months, keep them in a warehouse or special place at a great distance from your work area.
– If goods or documents are used almost daily, keep them near your work area.
2. Seiton (Set in Order)
– Organize the necessary items to make it easier when searched, also by labeling.
– Assign or rearrange storage space, shelves, cabinets, etc. (if necessary)
– Define the storage area limit
– Compile and put all items or documents in a designated place. Please provide item identification (label) to prevent usage / retrieval errors until the return of goods or documents
– For non-office, mark the floor marking to indicate storage area, work area, pedestrian area, entrance / exit, safety equipment, trolley area, forklift area, etc. Use standard color codes for pipes containing steam, water, gas, drainage, etc.
– Create a map or storage map
3. Seiso (Shine)
– Clean up the work environment, and remove dirt and clean the dust and keep everything clean
– Create a picket schedule and allocate responsibilities to employees to check and maintain daily hygiene, covering storage areas, equipment and environments (floors, walls, lights, etc.)
– Determine hygiene and inspection procedures
– Make a checklist covering all areas
– Checking and cleaning according to prescribed procedures
– Provide special space for storing hygiene kits and materials used for cleaning.
4. Seiketsu (Standardize)
– Using standardization methods to keep the seiri, seiton, and seiso conditions maintained.
– Establish a standard way of working to maintain cleanliness and tidiness
– Conduct checks by creating checklist forms against 3S and train employees how to do it
– Periodic evaluation based on checklist made
– Use visual management to recognize the non-normality of the process in a very fast time by anyone, the methods used include:
– Color codes, such as red for abnormal conditions and green for normal conditions
– Provides color codes on goods and tools that are the inventors of a particular area. For example red for production area, yellow for assembly area, and green for packing area.
5. Shitsuke (Sustain / Discipline)
– Shitsuke means to practice good work habits in maintaining other S, ie seiri, seiton, seiso, and seiketsu.
– Perform visual control in the workplace
– Building awareness by campaigning the 5S method. For example installing 5S stage poster, 5S slogan poster, etc.
– Create procedures on how and when 5S will be implemented
– Formulate audit guidelines or 5S implementation evaluation
– Provide management support with the formation of human resources and leadership
– Award the best employees who consistently apply the 5S stages.
That’s some implementation of 5s at workplace that you should try. This is for a better future.
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