Definition
5S
is a manufacturing philosophy that focuses on workplace organization,
cleanliness and standardization of work procedures. It is usually
applied in conjunction with lean manufacturing strategies. 5S is a
simple set
of techniques that remove waste from a work environment through
better workplace organization, visual communication, and general
cleanliness. The elements of 5S are defined as:
5S is intended to simplify the work environment, reduce waste, and reduce non-value activity while improving quality efficiency and safety. Because each of the five pillars begins with S, this method was named 5S.
Sort (Seiri)
The first S focuses on eliminating unnecessary items from the workplace. An
effective visual method to identify these unneeded items is called red
tagging. A red tag is placed on all items not required to complete your
job. These items are then moved to a central holding area. This process
is for evaluation of the red tag items. Occasionally used items are
moved to a more organized storage location outside of the work area
while unneeded items are discarded. Sorting is an excellent way to free
up valuable floor space and eliminate such things as broken tools,
obsolete jigs and fixtures, scrap and excess raw material.
Set In Order (Seiton)
This is the second S and focuses on efficient and effective storage methods.
This includes painting floors, outlining work areas and locations, using shadow
boards, and modular shelving and cabinets for needed items such as trash cans,
brooms, mop and buckets. This step improves the appearance of the work
environment and improves morale.
Shine(Seiso)
The next step is
to thoroughly clean the work area. Daily follow-up cleaning is
necessary in order to maintain a clutter-free workplace and
desirable environment. Workers take pride in a
clean and clutter-free work area and the effort helps create
ownership in the equipment and facility. It is much easier to identify
potential problems when the area is clean. Workers begin to
notice changes in equipment and facility location such as air, oil and
coolant leaks, repeat contamination and vibration, broken, fatigue,
breakage, and misalignment. These changes, if left unattended, could
lead to equipment failure and loss of production.
Standardize: (Seiketso)
Once the first three 5S's have
been implemented, next step is to concentrate
on standardizing best practices in the work area.
Sustain: (Sitsuke)
Sustain focuses on sustaining a new workplace paradigm and standard of work place organization.
The Issues
5s is used with a Lean Manufacturing strategy. It is good discipline for every company to follow. There is no question about the need to keep the workplace clean and organized. However, while a Lean Manufacturing strategy can be extremely effective, when planned and implemented correctly, 5S is superficial at best, and does not provide the level of results often expected.
Accordingly, superficial approaches generally do not achieve significant results. Quite often we will hear top executives claiming to be using Lean Manufacturing strategies and when we visit the site, we will discover they have simply used 5S, which only scratches the surface of changes needed to compete fiercely.
However, just like anything else, 5S is no panacea, nor should it be embraced as a religion. It is an operational philosophy that will improve the appearance, increase productivity(to a lesser extent) and improve morale. When employed in conjunction to much deeper and radical changes in production, such as Lean Manufacturing principles, the combination can provide a new dimension to competing: quickly introducing new customerized high quality products and delivering them with unprecedented lead times, swift decisions, and manufacturing products with high velocity.
Pragmatic Applications
5S Philosophy can improve appearance, productivity (to a lesser extent) and workplace morale. When used together with more radical Lean Manufacturing approaches, the combination can greatly simplify and improve a production process. Benefits are real and long proven for Lean Manufacturing. 5S alone has superfical results.
Our Approach: Tools from a Toolchest
Rockford Consulting Group applies concepts and technologies as the situation warrants, that will result in the ultimate benefit to our clients. We treat strategies, technologies, and methodologies as tools in a toolchest, and use them when they offer practical solutions and achievable results. We believe that each client situation is unique, with its own unique set of solutions. (Please see our Lean Manufacturing consulting services Lean Manufacturing Consulting Services )
Why Us?
Rockford Consulting Group can provide long-term assistance to many companies in a variety of industries. The firm has a cadre of the best supply chain consultants in the world today, providing high quality professionalism through the use of experience and innovation.
We subscribe to the Institute of Management Consultants Code of Professional Conduct. All consultants engaged on projects adhere to its principles. Whenever possible we will use consultants certified in their particular specialty area. Certification assures that consultants have substantial prior experience in their specialty, and their competencies have been tested by the IMC, and verified by a number of clients. This assures our clients that we are assigning the highest qualified consultants in the profession.
We provide technical expertise, team facilitation, leadership, and direction in deciding how you will meet the challenge. We refer you to our Qualification Statement for further details on our background, areas of specialization, concepts and technologies applied, staffing, operating policy, approach, companies and industries served, case studies and references. Equally as important, we train our clients to sustain new methods of manufacturing and the consequential benefits over time. Your company will benefit directly from this training.
We have achieved an efficiency in our approach to assignments that allows us to provide high quality technical and managerial advice in a much shorter amount of time than could be accomplished years ago. We are able to do this because of the extensive consulting experience that each of our specialists has.
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