5S: Getting your hands dirty to clean things up

If you read my first two blog posts about 5S, you should have a better understanding of the “what” and “why” of 5S. This blog will help you understand the “how.”

A detailed checklist is helpful to assure that cleaning materials, trash, temporary storage and other necessary items are in place to assure a smooth workshop. Participants report wearing work clothes as 5S requires folks getting their hands dirty.

On the day of the kaizen, (kaizen is Japanese term that equates to continuous improvement) event, the team receives an introduction to 5S and the steps they must follow. After moving to the project site, they spend a few minutes writing a “Purpose Statement” to guide their work. (This is where “effective isn’t perfect” comes into play – – the Purpose Statement might change but it helps organize thought to get going quickly.)

#1 Sort

• Items of no value are immediately trashed
• Items with value but not meeting the purpose of the area being 5S’d are sent to a temporary storage area for later disposition
• Consider the 7 Forms of waste in Sort and all steps of 5S. Remember the acronym COMMWIP:

1. Correction (Errors)
2. Overproduction
3. Motion (people)
4. Material movement
5. Waiting
6. Inventory
7. Process

• Items that are not present but could add value are identified for follow-up.

# 2 and # 3 Straighten and Shine

• Items are organized for easy access
• Everything is deep cleaned (more than a superficial wipe)
• The goal is to organize items most often used to be easy to see and easy to get.
• Steps 2 and 3 are usually done concurrently as dictated by common sense.

#4 Standardize

• Use labels, tape, written instructions and other forms of visual controls (e.g. colored stickers) to enhance understanding. Those who use the area should be able to quickly obtain what they need when they need it.
• This is the step where elements of the standard are written on an 8 ½ x11 sheet of paper adjacent to a plan view diagram of the area itself. This sheet is placed in a plastic protector and affixed to a wall in a convenient and visible location.

5 Sustain

• During the kaizen workshop, another 8 ½ x11 form is completed showing who is to do the inspection along with the second level person who validates that the inspection takes place as prescribed. It, too, is placed in plastic and affixed to the wall.
• The most difficult part of 5S is the ongoing part of sustain where the improvements made are maintained according to the standard.

5S Workshop Summary

• Usually takes 6-8 hours
• 30-80% savings in inventory and floor / shelf space is common
• Tasks associated with the project become faster and easier

The outcome is an organized area, but…
The real value is using 5S to help the team understand how to identify and eliminate waste of which safety of employees is foremost.

For more information on these and similar topics, you may be interested in joining the SHE, sustainability and lean group on LinkedIn