The 5S system or the 6S system? The 5S system is one of the fundamental tools that builds the Lean Management philosophy. Practice shows that most companies begin their adventure with lean manufacturing from the implementation of the 5S system. This is the correct approach, as this method is oriented towards the stabilization of processes, which is the foundation of the Toyota Production System. Unfortunately, the 5S system is very often associated by employees with just cleaning their workplace. If the 5S system ended with cleaning, we would only have 3 steps of this approach – cleaning is the 3.S. The 5S system primarily aims to improve and maintain the quality of the workplace. One of the guiding principles of the 5S system is: “Everything has its place and everything is in its place.”
Table 1 shows the procedure for implementing the 5S system at any workplace. This diagram was developed on a Job Breakdown Sheet used in the Training Within Industry – TWI program.
Table 1. Scheme of the procedure for implementing the 5S system
Important steps | Key points | Reasons for key points |
What should be done | How it should be done | Why should you do it this way |
1. Sorting | 1. Separating what is needed from what is not needed: -tools -instructions, -materials, -Etc. |
1. Maintaining order in the work station is easier when you only have at work what you need on a daily basis. |
2. Discarding any unnecessary parts or marking them with a red label | 2. If you are not sure whether to discard a given part, leave it in the red label area and return to it after a certain amount of time (e.g. a month). You can then take action. Throw away any unnecessary things. | |
2. Systematics | 1. Marking places for parts and tools that you need on work stations | 1. You will always know what you are missing on the work station. It will also be easier to keep order. |
2. Using colors (visual control) | 2. Colors are an essential part of visual control. People absorb as much as 83% of information through sight. Try to use colors wherever possible. | |
3. Defining limits, levels and directions. | 3. This will help you keep the required number of materials and tools on the work station. This will facilitate self-discipline in following the rules. | |
3. Cleaning | 1. When cleaning, looking for faults and problems on your work station | 1. Cleaning is checking. You do not clean just to keep the machine or work station tidy. The main purpose of cleaning should be to identify irregularities. |
2. Setting up a cleaning schedule | 2. Thanks to the schedule, you will be able to effectively audit the 5S system maintenance process in the company. | |
4. Standardization | 1. Establishing standards for cleaning and arranging tools and materials on the work station. | 1. The work station should be organized in such a way that everyone knows how to find themselves on it – not only you. The written standard will help with this. |
2. Establishing a schedule of audits | 2. To maintain the system. Only supervisions and audits are a guarantee that 5S activities will become a habit for employees. | |
5.
Self-discipline |
1. Carrying out the tasks that result from audits. | 1. An audit is not control. This is an opportunity for improvement. Expect audits at your work station. If any recommendations come from them, follow them. Self-discipline is about following the rules every day. Don’t be afraid of audits. Treat them as an opportunity to test your conduct. |
6S – Safety as the first or the sixth “S”?
How to implement O.S – occupational safety?
- Important steps (what are we doing?)
- Key points (how do we do it?)
- The reasons for the key points (why do we do it the way we do it?)
- Words that tell you to work safely
- Orders to use personal protective equipment
(Fig. 1). Hierarchy of control
- Step – Identification of the places that are the causes of hazards
- Step – Identification of remedial measures
- Step – Implementation of remedial actions.
- Step – Controlling the results
Table 2. Scheme of proceeding in the case of O.S – occupational safety
Important steps | Key points | Reasons for key points |
What should be done | How it should be done | Why should you do it this way |
1. Creation of a safe workplace | 1. Identifying places that are threats | 1. To determine where an accident could occur in the future. Use the hazard identification worksheet as inspiration. |
2.Defining countermeasures for threats | 2. To cover all the hazards that could lead to an accident. | |
3.Implementing countermeasures | 3. These measures will, in practice, protect employees. Remember to start with the elimination of threats, and then if it is impossible, implement technical measures. Treat personal protective equipment as the least effective measure. | |
4. Training employees about the hazards occurring on work stations | 4. So they become aware of possible dangers at a work station before they start implementing the 5S system. | |
5. Controlling results | 5. To check that countermeasures are in place and that no additional hazards have arisen. |
The 5S system or the 6S system? A summary
Dr. Bartosz Misiurek is a founder of Lean Community and Lean Management Token. He is a CEO at LeanTrix Global Company and a Member of the Board at Astral Hodling OU (IT Company). Author of the book “Standardized Work with TWI: Eliminating Human Errors in Production and Service Processes.” He works as Sr Manager at Automotive Company.