5S Implementation Methodology
5S implementation methodology is a system to reduce workplace waste and optimize productivity by
maintaining an orderly workplace. The use of visual reminders helps to achieve consistent
improvements as well. 5S Implementation “cleans up” and organizes the workplace, without changing
its existing configuration, and it is typically the first lean method which an organization puts
into effect.
The 5S pillars, Sort, Straighten, Sweep, Standardize, and Sustain, provide a methodology for
organizing, cleaning, developing, and sustaining a productive work environment. In order to have
a smooth and efficient flow of work, every company needs a system to organize and maintain the
work areas.
This lean manufacturing method encourages workers to improve their working conditions and helps
them to learn to reduce waste, unplanned downtime, and in-process inventory.
Typically, 5S implementation would result in significant reductions in the amount of space needed
for existing operations. It also would result in the organization of tools and materials into
labeled and color coded storage locations, such as the well known painted outlines of tools on
pegboard.
Another result is the creation of kits to organize specific activities. These kits save a great
deal of time and aggravation. You no longer need to gather the same items repeatedly for frequent
tasks; they are all in one place. Brilliant!
The approach to 5S implementation
5S is a cyclical methodology: sort, straighten, sweep, standardize, and sustain the cycle. This
results in continuous improvement. It is a never ending process that gradually improves
everything it touches.
The 5S Pillars
Sort. This focuses on identifying all unnecessary items from the workplace which are not needed
for day to day operations. These items receive a red tag and are placed in a central location for
everyone to see and decide what to do with. Many times these are useful items, but used so rarely
that they need to be discarded, given away or moved to a storage area.
It is surprising how much space can be liberated from just this one process. Vast amounts of
valuable floor space suddenly become available for more productive work.
Straighten. Once sorting has taken place, you create efficient storage methods so your items are
easy to locate and use, as well as put away. This would include labeling drawers, tool racks,
boxes, shelves, etc. You also will define areas such as storage, first-aid, shipping, etc.
As you can see, one S builds on the other steps; in fact, they are all integrated to form a whole
way of keeping a workplace orderly and efficient.
Sweep. This is sometimes referred to as shine as well. Sweep means to clean, to thoroughly remove
clutter and fix things. A daily follow-up cleaning is essential in order to sustain the new
improvements.
Everyone likes working in a clean environment, plus it often happens that damaged wires, pipes,
electrical outlets, etc. are discovered and repaired. This is also a safety feature of 5S.
It is also a good idea to establish targets before beginning your Sweep process. This helps keep
everyone focused and accountable.
Standardize. Once the first three 5S’s have been implemented, the next pillar is to standardize
the best practices in the work area. Individuals need to be assigned responsibility for each of
the first 3S aspects.
Then you can create procedure manuals, visual cues such as signs, schedule short blitzes to
maintain the first 3S procedures. This is important to prevent the procedures from breaking down and
getting dirty.
Sustain. This involves changing habits and is often the most difficult aspect of 5S
implementation…Changing entrenched behaviors can be difficult, and the tendency is often to
return to the status quo and the comfort zone of the “old way” of doing things.
Sustain focuses on defining a new status quo and standard of work place organization. Without the
performance reviews, and department tours. Organizations typically seek to reinforce 5S messages
in multiple formats until it becomes “the way things are done.”
The 5S circle is kept in motion by discipline. 5S training of everyone involved is essential to success as well, otherwise it will just be another program imposed from management. Often workers wondr what is lean manufacturing and when they see the positive results of 5S implementation, they will be much more enthusiastic.
Randy Hough
Plastic Injection Mold Maker
what is lean manufacturing
“You know Dad, I’ve been thinkin’, one is a lot more than zero!” my son, Thomas, age 5.
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