Tired of spending hours & hours in your workplace/plant/industry just to find the right thing you need. Fed up of not finding the right cutting tool to replace the broken one in an emergency?
5S Technique is the way to go!!
5S Technique of Lean Manufacturing is identified as one of the techniques that enabled Just in Time Manufacturing. 5S Technique promotes organization of the workplace complete with visual controls and order.
5S Technique is based on a simple principle: “a place for everything and everything in its place, when you need it”.
5S Technique is basically governed by 5 Japanese Words:
1. Seiri (SORT)
2. Seiton (SET IN ORDER)
3. Seiso (SHINE)
4. Seiketsu (STANDARDIZE)
5. Shitsuke (SUSTAIN)
Now lets get to know these in detail:
1. Seiri (SORT)
This step involves sorting out the clutter within the work area. This stage involves eliminating all the unwanted items and keep only those items that are required.
An easy way of sorting is to use the Red Tagging Method. This method involves Red tagging all the unwanted items in the work area (refer Figure 1)
The simple Red Tagging criteria:
• Frequency of use
• Place of storage
• Item category
• Necessary / Un-necessary
2. Seiton (SET IN ORDER)
After the removal of all the clutter and unwanted items, this step involves arranging the essential items in an efficient manner through the use of ergonomic principles and practices.
The following methods can be adopted for the implementation of this step:
• An address system can be used to identify plant locations, storage area, shelf locations, etc.
• Place borders around the tools & equipment that are placed on the floor. This helps in easy identification of the equipment as well as warns the passersby to not get too close to the equipment.
• Label the tools & equipment for easy cross-identification with storage location markings.
• The use of pictures and graphics help in faster recognition of the items.
• After this step is complete, ‘After’ pictures of the area must be taken for own future references.
3. Seiso (SHINE)
The third step of 5S Technique is the SHINE procedure. This step is all about getting the workplace free from any kind of dust, dirt, fluids or any other debris. This can be achieved by following these three activities:
• Cleaning Supplies: The workplace should be equipped with the right and adequate cleaning supplies which have been tested in the past so that they do not harm any equipment or the work areas.
• Cleaning Method: Each team member should follow the same standardized procedure of cleaning the workplace. This helps maintain uniformity in the workplace.
• Cleaning Schedule: A proper cleaning schedule should be made so that each team member is aware about their duties and the time frame as well.
4. Seiketsu (STANDARDIZE)
This step is all about establishing the improved workplace practices as a Standard for each and every member of the team to follow. This helps to maintain the clutter free workplace. Standardization can be implemented using the following:
• Colour Coding
• Checklists
• Standards
• Roles & Responsibilities: These must be clearly defined and consistently applied
• Each area could have different methods for accomplishing the specified tasks. All the team members must receive training in their area of work.
• The tools used for standardization should be unified across all areas of the workplace.
5. Shitsuke (SUSTAIN)
The purpose of this step is to maintain the momentum generated in the initial stages. This can be done by implementing the following techniques:
• Auditing: Management Audits should be held regularly to ensure that the routines and schedules specified as Standard, are being carried out properly. This also makes the employees understand that maintaining the level of workplace organization is a top priority.
• Reward & Recognition Programmes: The team and its members who perform their tasks properly should be rewarded, so that they are always motivated to improve and maintain the workplace.
• Training Programmes: Camps or Programs should be held in order to train the existing as well as new team members about the new techniques and methods of 5S Technique.
• Review Meetings: Conducting regular review meetings help in order to rectify any issues in the existing plan as well as look for additional 5S Technique opportunities.