Lean and Six Sigma are the two of today's most popular business improvement approaches. Six Sigma drives improvements in quality and reliability by reducing variation using a problem-solving method known as DMAIC, define, measure, analyse, improve, and control. Lean is a proven approach to eliminating waste in new product development, manufacturing, and distribution in order to cut lead-times and investment, increase flexibility, and reduce costs. Lean involves using as little as possible of the available resources to deliver value to customers.
When a company-wide lean or Six Sigma program is begun, the first challenge that managers and improvement teams face is knowing exactly where to begin improvement efforts. Waste elimination is contingent on first being able to identify waste. Likewise, it is difficult to pinpoint root causes of variability in an unstable work environment. In many workplaces, fire fighting is common, and problem solving is reactive rather than proactive. Trying to implement an improvement program in such an environment is a formidable challenge.
This is where 5S comes in. 5S is an approach to waste and variability identification and elimination that relies on stabilizing the work environment. 5S is a simple and immensely practical approach to improvement that can achieve great results in a short time.
5S steps
Sort
In the sort step, necessary items for the workplace are separated from unnecessary items and subsequently removed. A red tag campaign is conducted to evaluate items based on their usefulness and frequency of use. Unnecessary items crowd the workplace and make it difficult to find and keep important items near the work area. These items can include obsolete equipment and inventory, broken tools, scrap, old files, etc. Safety and productivity are improved as a result of the extra floor space created.
Set-in-Order
This step involves installing systems so that necessary items are always located in logically predetermined locations. Based on the inventory classification of the red tag campaign, items are placed in locations based on frequency of use. Frequently used items are placed at or near the workplace while infrequently used items are stored in specified locations. When items are stored in logical places, employees don’t waste time looking for the appropriate tools or fixtures. The gold standard is a workplace organized in a way that items can be retrieved within 30 seconds with a minimal number of steps.
Shine
The third step consists of regular cleaning activities that minimize machine downtime.. Observers are amazed when they see how incredibly clean the shop floors are of world-class Japanese manufacturing plants. Daily cleaning of machines and production areas reduces breakdowns and maintenance costs while improving safety and quality.
Standardize
The goal of this step is to maintain best practices in the work area. This is achieved by providing visual warnings as well as standardized work methods and procedures. Equipment is marked and labeled so that observing and inspecting equipment can be conducted easily. Anyone on the shop floor should be able to determine when a piece of equipment is malfunctioning, increasing response times and reducing downtime.
Sustain
This last step involves developing habits to implement the 5S philosophy on an ongoing basis. If 5S is to be successful, a regular, detailed appraisal of the workplace is recommended. This audit ensures that the focus remains on maintaining the new standard or workplace organization.
It's clear that 5S is much more than just a housekeeping program. It is a structured program that results in dramatic changes and equally dramatic results.
Benefits of 5S
Less Waste Equals Improved Efficiency
A key principle of 5S is to get rid of items that are not used, and make it easier to find items that are needed. This gets rid of clutter, unnecessary tools, scrap materials and unused supplies. It organizes, labels and places close at hand those tools and materials that are needed on a regular basis. The result is that time is spent more productively and less time is wasted finding needed tools and materials.
In 5S, materials, tools, machines and equipment are positioned in ergonomic locations. This helps reduce fatigue, quickens access, and results in a more efficient workplace. Ergonomic positioning helps to address and eliminate the seven wastes.
Standardization is also a part of 5S. Standardization ensures that the most efficient work practices are identified and used, and that wasteful work practices, unnecessary tools, unused materials are eliminated.
Less Space Used For Storage Equals Reduced Costs
By eliminating unused materials, tools and equipment, and getting rid of clutter, a surprising amount of space will free up. There is a cost associated with space, not only in the rental or lease costs, but in heating/cooling, cleaning and maintaining of that space.
Clean Equals Improved Maintenance & Less Down Time
When machines, equipment, and tools are kept clean and free from clutter, it is easier to spot defects, part failures, and problems such as an oil leak. This allows preventative maintenance to address the problem before it becomes a more serious problem.
For example, if a machine is kept clean, an oil leak would immediately be noticed. The source and cause of the leak can be quickly identified and the problem fixed, before low oil levels lead to more serious damage to the machine.
Implementing 5S Equals Improved Safety
· Cleanliness ensures spills get cleaned up ASAP, eliminating the potential for slips and falls.
· Clutter is removed, revealing hidden electrical, chemical or mechanical hazards.
· Having needed tools, materials and supplies close to where they are needed greatly reduces travel (movement) and as a result reduces the potential for injury.
· Employees who have their eyes open for spotting ways to improve using 5S principles will be more aware of their surroundings and potential safety hazards.
Improved Morale Equals Greater Commitment to Job
When your employees see you care about them, their work area, and that you value their input, they care more about their job. The clean, organized workplace that results from 5S is a more pleasant workplace that leads to improved employee attitudes. The focus on cleanliness, organization, labour saving efficiency, having the right tools, and using quality standards leads to an increased pride in workmanship.
Add in the improved safety (lower numbers of injuries) resulting from 5S and you get a workforce that is happier (less turn-over), more motivated, is getting more done with less effort, and is interested in improving their workplace and your products.
5S Summary
5S is one of the most cost-effective lean techniques available, and it is the foundation to all other lean techniques. That makes 5S the perfect starting point for bringing the benefits of lean to your workplace.
