Tools - 5"S" (Workplace Organization)

5S Workplace Organization

5S is the name of a workplace organization method that uses a list of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. When transscribed into English, they all start with the letter "S". The method is normally applied to manufacturing workplaces but could just as well apply to a store, an office, or technical department where critical methods, hardware, and tools need to be closely monitored. The list describes how to organize a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new order. The decision-making process usually comes from a dialogue about standardization, which builds understanding among employees of how they should do the work.  5S is one of the foundation tools for Lean Manufacturing.

Sorting (Seiri)

Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so forth in the plant and work area. Keep only essential items and eliminate what is not required, prioritizing things per requirements and keeping them in easily-accessible places. Everything else is stored or discarded.

Stabilizing or Straightening Out (Seiton)

There should be a place for everything and everything should be in its place. The place for each item should be clearly indicated.

Sweeping or Shining (Seiso)

Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of each shift, clean the work area and be sure everything is restored to its place. This makes it easy to know what goes where and ensures that everything is where it belongs. Spills, leaks, and other messes also then become a visual signal for equipment or process steps that need attention. A key point is that maintaining cleanliness should be part of the daily work – not an occasional activity initiated when things get too messy.

Standardizing (Seiketsu)

Work practices should be consistent and standardized. All work stations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's.

Sustaining the Practice (Shitsuke)

Maintain and review standards. Once the previous 4 S's have been established, they become the new way to operate. Maintain focus on this new way and do not allow a gradual decline back to the old ways. While thinking about the new way, also be thinking about yet better ways. When an issue arises such as a suggested improvement, a new way of working, a new tool or a new output requirement, review the first 4 S's and make changes as appropriate.It should be made as a habit and be continually improved.

There are many tools available in the marketplace to help you with these areas. The key to the implementation of 5S is employee understanding and buy-in.  Training is always a major component of success.  Do not overlook its importance.  5S is one of the foundations of Lean Manufacturing and must be in place before you can move into other areas.

Simplified: SORT - STRAIGHTEN - SHINE - STANDARDIZE - SUSTAIN

First Step: SORT - Clearly distingquish needed items from unneeded and elimate the latter

Second Step: STRAIGHTEN - Keep needed items in the correct place to allow for easy and immediate retrieval

Third Step: SHINE - Keep the workplace neat and clean

Fourth Step: STANDARDIZE - The method by which Sort, Straighten, and Shine are made habitual

Fifth Step: SUSTAIN - Maintain established procedures

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Where do I start? FIRST of Series

How can I implement Lean Leadership principals and programs with limited or no consulting services?

So many great ideas fail because of execution, not because the idea was bad.  It is the same with Lean Leadership principals and programs.  There are many opportunities for success - pushing your business to new heights with record profits.  There are also opportunities to add cost without seeing a return. I have seen how six-sigma programs, TQM, Leadership Programs and other processes have both helped and hindered companies. As the leader of your organization you must be sure you understand and internalize your path to success.  This blog is intended to help you understand the areas to focus on, the tools needed, where to find help, and to recognize when you really do need to seek expert advise.  This blog and its many posts can help you follow a path to understanding.  Along the way you will learn many things, however be ever aware that few can go it alone!  We can always learn from the experts and often they are the only ones who can push us along to achieve our goals. The path to "Lean Leadership" is not a walk in the park.  However there are many opportunities to take advantage of principals and tools which can be implemented in a logical order over a period of time.  Keep in mind that Lean Leadership is a process, not a single action.  You need to start somewhere, why not here.

Training and continuous Learning are the keys to success.  Everyone in the organization must be challenged constantly.  Training and Learning opportunities must be made available to encourage new thinking.  Implementing the ideas in this blog along with support and training where needed will get you on your way to success with limited costs.  Try for some small successes before taking on a complete culture or organization change.  Look for some 'quick fixes' to use as learning opportunities.

The main thing is not to take on too much until you and your organization have a solid foundation in the process tools you will use.  There are so many "tools" out there that you can get lost in the process.  Be careful when hiring consultants to help you.  Many of them are great and are really there to help... because they enjoy seeing people and companies succeed.  However, others are there to just generate cash flow for themselves or their company.  There are many one or two person consultation groups out there at very reasonable costs to work with you.  These individuals will have a personal, vested interest in your success.  Give the 'new guy or the lone consultant' a chance to provide you with the services you need.  These folks often have very reasonable daily/hourly rates that can be one half of the big guys rates and will provide focused results. They will not have all the fancy 'glossies' but will have the knowledge.

Try out some of the principals and processes outlined in this blog such as those shown on pages:

1. Strategy Factors
2. Success Path
3. Process Tools
4. How to...?
5. Lean Leadership

These pages will link you to many other posts that will show you the path!  It is also important to review many of the archived posts and subscribe to this blog to get the latest posts on your path to success.

Also see:
Where do I Start? SECOND
Where do I Start? THIRD