Lean Initiatives The 5S Methodoloty and Practice of 5S

5S is the first in a continuous series of Lean Manufacturing and the component of 5S to give a framework of Efficiency and continuous improvement methodically make your work more efficient, as well as            originating better methods and influencing both worker complacency, and finally your subordinates.

While we are practicing Lean Six Sigma (LSS) and according to Lean Six Sigma we are considering 5S as a tool, it is more than that. The abbreviation of 5S from the Japanese words Seiri, Seiton, Seiso, Seiketsu, Shitsuke, is not just a system, it is a culture that has to be implemented into any Organization which’s goals are too spontaneous and successive implementation of working environment and working states. 

Lean initiatives mean the exclusion of all waste in any Manufacturing, Work Staton, Store room, Warehouse, and Third Party Logistics (3PL) provider. It can be implemented at office with permission of top management.

Once upon a time when Henry Ford was building automobiles, there was tools hanging on a board outlined by the tool shape, so one took the tool off the board and used it, and he had to bring it back to the same identical spot. It was not called a Lean initiative, 5S or even “shadow boarding” back then. It was called a good, old common sense approach to tool management.

That is, place like tools and equipment in the same area. All the tools are must be visual and  keep everything within reach. The workplace must be organized and use the KISS method; Keep it Simple and Stupid so anyone can find and use tools readily and know immediately where to return them for re-use.

[Note That: 5S is only the start to implementing all Lean initiatives, by using basic organizational  skills first, 5S is only one of many LEAN Methods.]

The Japanese developed this simple and easily understandable words and religiously followed the philosophy of 5S in every aspect of their life and spread it worldwide. Today these 5S’s are world wide recognizable system.

If the 5S philosophy is confined to one classroom training season or, at best, used as a one-time implementation methodology that then dies its own death due to negligence. 5S is not a list of action items that has to be reviewed at some interval of time. It has to be practiced as a daily routine, which needs concentration, dedication and devotion for sustaining it and it and ultimately making it a company as well as a worldwide culture.

An appropriate and frequent process has to be followed to make 5S a practice and a success.

PDCA or Plan-Do-Check-Act:

The PDCA (Plan, do, check, act), or “De ming cycle,” of implementing 5S is effective. This is a Never dying  process has to be followed willingly.

Basically 5S mean having visual order. The 5 components of 5S are: Sort, Set In Order, Shine, Standardize and Sustain. First, sort everything out, set it in order, clear it all up, so it shine, make sure everything is standardized, and the toughest part is of 5S is to sustain and control the 5S administrative systems, with negative and positive reinforcement, so it takes In place permanently. After Implementations are being successful, then it needs to be written or documented. These Standard operating Procedures (S. O. P.s) are useful to ensure that,

When new persons or new employees joining in the company, he/she must have to educate in 5S before they work.

Benefits of 5S:

Improve safety,decrease NPT or Non Productive Time, raise employee morale, identify problems more quickly, develop control through visibility, establish convenient  work practice, increase product and process quality, strengthen employees, pride in their work, promote stronger communication among staff, and empower employees to sustain their work area, 5S can increase morale, create positive impressions on customers, and increase efficiency and organization. 

 Md. Farid Ahmed
IE Officer
Fakir Apparels Ltd.
BSCIC Industrial Area, Enayet Nagar,
Fatulla, Narayangonj, Bangladesh.
Mobile: 8801814220987
E-mail: farid.ieconcern@gmail.com