5S The Work Place management System

 History

  5S is a systematic approach to workplace management it was developed by Japanese. 5S is widely used in manufacturing industries to improve efficiency, safety, and organization. Implementing 5S principles in a manufacturing setting can lead to benefits such as increased productivity, reduced waste, improved safety, and better overall organization and morale among employees. It's an integral part of lean manufacturing and continuous improvement methodologies

There are five words in it which are expressed in Japanese words as follows.

1. Seiri (Sort)
2. Seiton (Set in Order)
3. Seiso (Shine)
4. Seiketsu (Standardise )
5. Shitsuke (Sustain)

 

  Seiri (Sort)

     Remove unwanted things from the workplace is called Seiri (Sort)

 How 

   Use Red Tag , Red Tag Register, Red Tag Area, and Quarantine area to implement Seiri at work place.

 Red Tag 

1. Identify the unwanted material from the workplace and use red tag to identify those materials are to be removed from the workplace
2. Unwanted materials may be, unused items, tools for long time, Worn out tools, excess material which occupies the space and hindrance to day to day working. 
3. Red tag shall contains, item details, quantity, Value (Price) , condition(Working or repair.. etc.,)  of the item.

Red Tag Area

   Identify the area to keep all red tagged items. It should be centre of the shop so that top management can see everyday and take action against it.

 Red Tag Register

   While putting red tag items in the area enter the details in register which is called red tag register. It should be reviewed every week by the 5S zone leader, Coordinator and take appropriate action

 Quarantine Area

   This is also similar to Red tag area but the items kept here are not being used for long time and it may be required in future, like some fixtures are not in use because of some projects are under hold.

 

Seiton (Set in Order)

    After removing all the unwanted items from the workplace we can arrange them , which should be easily accessible to the user. So we follow PEEP (place for everything and everything in its place)

 How 

1. Identify the items by labelling
2. Identify a place for each item 
3. Arrange all items in their place
4. User has to be practiced to keep the items in the place ( Trained and monitored)
5. At the end of each shift PEEP has to be ensured

 Examples.

Files can be arranged in rack with numbering (1,2,3,4). If anything is missed can be easily traced out visually.

Make shadow box for tools. 

 

Seiso (Shine)

     Cleaning the workplace as a practice which will enable the user to do inspection of the workplace. While touching and cleaning the machines, we will be able to know, is there any abnormality in the system. so that we can find out the issue and sort it out immediately. it will avoid downtime of the machine. Major breakdowns can be avoided. Workplace also will be clean. 

How

1. Identify the areas for cleaning
2. Provide all the cleaning materials
3. Make checklist with daily weekly monthly schedule

Seiketsu (Standardise )

    The method of doing 5S at workplace needs to be standardized. Document the best practices being followed and make it as SOP(Standard Operating Procedure). so that everyone will follow the same and achieve the same results and it needs to be reviewed month on month and improve it.

 How

1. Red tag procedure
2. Preventive Maintenance checklist ( used to ensure cleaning)

Shitsuke (Sustain)

    After implementing the 5S it is is very important to sustain the level and improve it.

 How

1. Training of personnel and refresher training on regular interval.
2. Monitor the implementation and talk with the person who are working and ensure that 5S is implemented in their blood.
3. Regular audits at workplaces and surprise audits
4. Motivation talks
5. price for winners

Implementation

    It is management commitment and employee involvement to implement 5S at workplace.

 How

1. There should be an implementation team to implement 5S at workplace, which involves coordinator , 5S zone leader, team members.
2. Monitoring should be done by top management every week.
3. There should be a layout clearly indicate 5S zones and it should be displayed in each corner of the workplace.
4. Each zone should have the display board contains zone leader and team member with 5S score for the week.
5. Coordinator should facilitate the implementation of 5S by providing materials and giving adequate training,  facilitate 5S audits and display scores and report to top management about the progress
6. Team member should actively participate and implement new ideas at workplace by means of kaizen 

The Benefits of Implementing 5S

Improved Efficiency: 5S optimizes workspaces, making it easier for employees to find tools, equipment, and materials. This reduction in wasted time and effort leads to improved efficiency and productivity.

Enhanced Safety: A well-organized and clean workplace reduces the risk of accidents and injuries. Safety-critical items are clearly labeled and stored in accessible locations, ensuring a safer work environment.

Streamlined Processes: 5S identifies and eliminates bottlenecks, redundancies, and inefficiencies in processes. This streamlining results in smoother operations and faster task completion.

Reduced Downtime: With organized and labelled tools and equipment, employees spend less time searching for what they need. Reduced downtime leads to increased production and less idle time.

Improved Quality: 5S helps maintain a consistent and organized work environment, which leads to better product and service quality. It minimizes errors and defects.

Cost Savings: By optimizing resource usage and reducing waste, 5S often leads to cost savings. This includes lower material costs, reduced maintenance expenses, and better inventory control.

Employee Morale: A clean, organized, and efficient workplace boosts employee morale. It creates a more pleasant work environment and fosters a sense of pride in one's work.

Higher Employee Engagement: Involving employees in the 5S process by giving them ownership of their work areas and encouraging their suggestions for improvements can lead to higher engagement and job satisfaction.

Clarity and Consistency: Standardized procedures and visual cues, like labels and color coding, create a clear and consistent work environment. This minimizes misunderstandings and mistakes.

Resource Efficiency: Proper maintenance and organization extend the useful life of tools, machinery, and materials. This results in efficient resource usage and less waste.

Reduced Inventory Levels: By eliminating unnecessary items and implementing inventory control measures, organizations can reduce excess stock and holding costs.

Continuous Improvement: The 5S methodology encourages a culture of continuous improvement, where employees are actively involved in identifying and solving problems. This culture fosters innovation and ongoing enhancement of processes.

Conclusion

    5S is the base of every manufacturing industry. It facilitates the implementation of all other systems easily. Visual workplace management improves the productivity and reduce the downtime of machines. The moral of the employee improves.

Notes :

Before implementing 5S, You should understand about Muda, Mura, and Muri ...

Muda - 8Type of Wastes in manufacturing process

Muda - in consistence in Process   

Muri  - Physical strain in process - (Fatigue to worker) 

The above things will get reduced or eliminated once you implement the 5S.

What is 5S?

How to implement 5S?

Basic understanding about 5S?

5S waste elimination technique?

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