Quality Environment (QE/5S)

 

What is 5S?

5S is a system for organizing spaces so work can be performed efficiently, effectively, and safely. This system focuses on putting everything where it belongs and keeping the workplace clean, which makes it easier for people to do their jobs without wasting time or risking injury.

 

5S Translation

The term 5S comes from five Japanese words:

  • Seiri
  • Seiton
  • Seiso
  • Seiketsu
  • Shitsuke

In English, these words are often translated to:

  • Sort
  • Set in Order
  • Shine
  • Standardize
  • Sustain

Each S represents one part of a five-step process that can improve the overall function of a business.

 

The Origins of 5S – 5S & Lean Manufacturing

5S began as part of the Toyota Production System (TPS), the manufacturing method begun by leaders at the Toyota Motor Company in the early and mid-20th century. This system, often referred to as Lean manufacturing in the West, aims to increase the value of products or services for customers. This is often accomplished by finding and eliminating waste from production processes.

Lean manufacturing involves the use of many tools such as 5S, kaizen, kanban, jidoka, heijunka, and poka-yoke. 5S is considered a foundational part of the Toyota Production System because until the workplace is in a clean, organized state, achieving consistently good results is difficult. A messy, cluttered space can lead to mistakes, slowdowns in production, and even accidents, all of which interrupt operations and negatively impact a company.

By having a systematically organized facility, a company increases the likelihood that production will occur exactly as it should.

 

Benefits of 5S

Over time, the 5S methodology leads to many benefits, including:

  • Reduced costs
  • Higher quality
  • Increased productivity
  • Greater employee satisfaction
  • A safer work environment

 

SORT (SEIRI)

Any work area should only have the items needed to perform the work in the area. All other items should be cleared (sorted out) from the work area.

 

SET IN ORDER (SEITON)

Organise and store neatly, easily retrieved and restored in-place.

 

SHINE (SEISO)

Clean the workplace and equipment on a regular basis in order to maintain standards and identify defects.

 

STANDARDISE (SEIKETSU)

The process of ensuring that what we have done within the first three stages of 5S becomes standardized; that is we ensure that we have common standards and ways of working.

 

SUSTAIN (SHITSUKE)

Disciplined and understand the guidelines and standards that have been determined to create a quality culture in the workplace.

 

Getting Started with 5S

Even though 5S is a fairly simple concept, beginning a new 5S program can feel daunting. It's like undertaking a big cleaning project in the garage or the basement at home; there's a lot of stuff to deal with, and getting started probably doesn't sound fun.

Start with practical steps such as deciding which departments and individuals will be involved, what training is needed, and what tools to use to facilitate the process. Determining these concrete things will help begin the process of 5S implementation.

 

Who Should Participate in 5S?

Here's the short answer to this question: everyone. If a department is starting 5S, managers and all other employees should be included. If anyone is left out, this could lead to confusion or to messes that people don't want to take ownership of.

It is possible that some people will play a bigger role in 5S than others, which is fine. There might be 5S coordinators who are in charge of installing and maintaining 5S labeling, keeping tracking of assigned tasks, or introducing new department members to the 5S system. These people will obviously spend a lot of time thinking about 5S compared to others. Everyone should think about 5S regularly, though. 5S might initially take place as an event, but ideally it becomes a part of daily work for everyone.

It's also important to remember that company leaders should participate in 5S, especially if 5S is a company-wide effort. When people see their superiors taking 5S seriously by participating in it, they'll be more likely to take it seriously, too.

 

5S Training

Anyone who will participate in 5S activities needs to receive training. This could be done in a classroom setting, with a training DVD, and/or through hands-on activities. A demonstration of how 5S could occur at a workstation might also be useful.

For employees to understand why the company is going to start using 5S and why it's important, they should be given a brief history of 5S, its parts, and its benefits.

It's quite possible that the way 5S is carried out at one organization or even one department will be different from others, so groups performing 5S for the first time may need to work out the best way to perform the steps of 5S in their spaces.

In any case, everyone should receive training when 5S is new, and then any new employees who come on board later should receive training about 5S as well.

 

5S & Visual Communication

A key part of 5S is that it makes spaces cleaner and therefore easier to navigate. That means people can more easily get their work done. Visual communication tools such as labels, floor markings, cabinet and shelf markings, and shadow boards can make navigating spaces even simpler. Plus, these tools can help keep the workspace organized. A workplace that uses visual management in this way is often referred to as a visual workplace.