5S - Workplace Organisation... And Much More!

5S is a structured approach to Workplace Organisation

5S is in place in ALL world class organizations

        5S 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.

5S Step 1 (Seiri)

Clearout and Classify

Identify

ä                                                 what you KNOW you definitely need all the time.

ä                                                 what you KNOW you definitely need occasionally.

ä                                                 what you THINK you might need in the future.

ä                                                 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 1 (Seiri)

Eliminating Waste - Action at the source

7 steps to follow :-

1.         Determine the extent of the dirt / leakage's.

2.         Undertake major cleaning.

3.         Investigate the reasons why.

4.         Determine the worst locations within site / area.

5.         List up the reasons in detail.

6.         Decide on an effective Action Policy.

7.         Budget and schedule implementation plan (if necessary).

5S Step 2 (Seiton)

Configure

Put Everything in its correct place

ä                     Organise storage for all equipment i.e. what, where, how many.

ä                     Frequency of use defines location relative to point of use.

ä                     If its used frequently keep it close / low frequency store offline. 

ä                     Shop organisation must have clear walkways, work areas, rest areas. etc.

ä                     Consider using different coloured floor areas to highlight walkways, work, storage areas etc.

ä                     All essentials such as fire extinguishers  and safety equipment must be visible

          and easily accessible.

The place must be

ä                                                Appropriate to usage

ä                                                Well maintained

ä                                                Tools Easily located

ä                                                Tools / locations Clearly identified

5S - A place for everything and everything in its place

Step 3 (Seiso)

Clean and Check

Regular cleaning schedules are required

ä                      Create a clean and tidy working environment and maintain it.

ä                      Define responsibility zones for cleaning areas, and clarify roles and responsibilities.

ä                      Develop regular routines for maintaining a clean environment (e.g.. 5min 5S etc).

Cleaning must become an activity which is

ä                                                 Ongoing

ä                                                 Monitored

ä                                                 A source of pride

ä                                                 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)

Conformity

Good Housekeeping

ä                     Decide what is classed as an abnormality and make it visible to the operator.

ä                     Design clear, standard labels for locations, tools, machine conditions and locate them in standard positions.

ä                     Provide indicators where limits can be exceeded.

ä                     Draw position markers in places where items are removed and returned.

Agree and set :

ä                                                 Standards of cleanliness.

ä                                                 Procedures for maintaining standards.

ä                                                 Standard marking and labelling of all items.

ä                                                 Standard methods for indicating limits, identifying locations, etc.

The system must be controlled and maintained.

Step 5 (Shitsuke)

Custom and Practice

Adhere to the system rules

ä                      Develop and maintain habits through training and discipline. (At all times)

ä                      Use visual rather than verbal communication to train for new procedures.

ä                      Involve everyone in the development of standard documentation.(e.g.. Checksheets etc.)

ä                      Be conscious of time (3-10min 5S).

It is important to maintain discipline

ä                                                  Incorrect practices must be identified.

ä                                                  Correct practices have to be taught and demonstrated.

ä                                                  Ensure everyone's understanding and agreement.

Without training and discipline the other steps will fail

The building block for continuous improvement - 5S