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Manufacturing Floor Ideas for Each Element of 5S

Posted by Noah Paratore

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Jan 21, 2021 11:13:00 AM

iron works steel and machine parts modern factory indoor hall5S is a Lean manufacturing technique that addresses the organization of workspaces and processes for a safer and more efficient manufacturing facility. It is called 5S because the five steps in this Lean tool, sorting, setting, shining, standardizing, and sustaining, all start with the letter S in both English and Japanese.

While this post is geared toward manufacturers' needs, the 5S technique can be of great value in other environments, such as healthcare and office settings.

Seiri – Sort

This is the first step of a 5S implementation. Process operators go through the workspace to determine what is needed for the task or manufacturing process. Workers should remove everything not required to complete the process from the work area.

Utilizing 5S red tags can be useful during this step. Workers attach red tags to items or equipment whose immediate use or need is not apparent. This tagging approach goes hand in hand with a "red tag area," which is a specific holding space for the tools and equipment to be later assessed and determined whether or not it should be removed, recycled, or relocated to a different department.

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Seiton – Set in Order

Once the workspace only contains necessary supplies, the next step is to set it in order. This step ensures that all items have a designated home. Team members map out where tools and equipment will be placed and decide on a logical order for them to be set to reduce the waste of extra movement.

Shadow boards and floor markings are useful tools for organization. Shadow boards have specific outlines behind or beneath where tools hang or sit when stored. These silhouettes make it evident to workers where to replace tools, and they make it easy to identify what tools are missing. Custom floor signs are another clear visual indicator of homes for specific items on the factory floor like garbage cans or wash stations.

Seiso – Shine

Up next is the cleaning, sweeping, and shining of the newly sorted and set area. A clean manufacturing workspace is a safer and efficient workspace. Also, being proactive in your efforts will keep your facility organized well after the five-step process is complete, and it will set an example for workers that a "shined" workplace is expected.

Equipment should be painted if necessary, maintenance should be completed on machines, floors should be swept, and floor tape replaced if needed. Make sure workers have all the cleaning supplies required to get this job done.

Seiketsu – Standardize

Don't let your team's hard work from the previous steps go to waste. Standardize 5S operations in your facility. Employees will understand what is expected of them once a clear and documented system is implemented. Look at the first three S's in the process and create standards and procedures for how and when these tasks will be repeated. Ideally, you'll store this Standard Work in your manufacturing improvement software platform, which everyone can access as needed.

Online audit sheets allow you to create a checklist specifically for your facility and 5S process. You can create audit sheets to be used by whoever is evaluating an area on any given day. You might also think about ramping up your visual communication efforts and hang posters and signs reinforcing the process, 5S principles, and expectations.

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Sustain – Shitsuke

Once your facility is up to the standards you set, attention turns to sustaining the new practices maintaining discipline. This focuses on turning 5S from an event into a continuous way of working.

At this point, culture and consistency are essential. When workers see that leaders are willing to invest time and resources into 5S, and when workplace organization is a common topic, they will live up to expectations.

5S can seem like a big ask system, one that may even seem too daunting to tackle. But once you go through the process, the result will be a clean, safe, efficient, and well-optimized space that will benefit everyone.

Topics: 5S

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