5S/ 6S Concept

5S- (Seiri –Seiton – Seiso –Seiketsu – Shitsuke)

We consider 5S and Visual Controls to be the foundation of Lean Manufacturing systems. 5S and Visual Controls are workplace organizational tools that provide the necessary groundwork for workplace improvement. 5S and Visual Controls ensure that there is a place for everything and that everything is in its place—clean and ready to use.

                                           

                                          

6S (5S+Safety)

6S is modeled after the 5S process improvement system designed to reduce waste and optimize productivity in the workplace by:

•          Creating and maintaining organization and orderliness

•          Using visual cues to achieve more consistent operational results

•          Reducing defects and making accidents less likely.

The Six Pillars of 6S

1. Sort (Get rid of it): Separate what is needed in the work area from what is not; eliminate the latter

2. Set in order (Organize):  Organize what remains

3. Shine (Clean and Solve):  Clean and inspect

4. Safety (Respect workplace and employees):  Create a safe place to work

5.  Standardize (Make consistent): Standardize the cleaning, inspection, and safety practices

6. Sustain (Keep it up):  Make 6S a way of life.

Relationship of the 6S Pillars:

                               

Pillar 1: Sort (Get rid of it)

» Focuses on eliminating unnecessary items from the workplace that are not needed for current production operations

» Uses visual methods such as red-tagging to identify these unneeded items

» Involves evaluating the necessity of each item in a work area and dealing with it appropriately

» Can help reclaim valuable floor space and eliminate broken tools, scrap, and excess raw material.

Pillar 2: Set in Order (Organize)

» Focuses on creating efficient and effective storage methods

» Arranges items so that they are easy to use

» Labels items so that they are easy to find and put away

» Can only be implemented once the first pillar, Sort, has cleared the work area of unneeded items

» Strategies include:

•          Affixing labels and placards to designate proper storage locations

•          Outlining work areas and locations

•          Installing modular shelving and cabinets.

Pillar 3: Shine (Clean and solve)

» Focuses on thoroughly cleaning the work area

» Daily follow-up cleaning is necessary to sustain improvements

» Enables workers to notice malfunctions in equipment such as leaks, vibrations, breakages, and misalignments that could lead to loss of production

» It is a good idea to establish Shine targets, assignments, methods, and tools before beginning the Shine pillar.

Pillar 4: Safety (Respect workplace and employee)

» Focuses on eliminating hazards and creating a safe environment to work

» Once the workplace has been organized and cleaned, potential dangers become easier to recognize

» A separate “safety sweep” should be performed to identify, label, and deal with hazards

»Safety measures can also be implemented in conjunction with strategies in the other five pillars.

Pillar 5: Standardize (Make consistent)

» Used to maintain the first three pillars

» Focuses on creating a consistent approach with which tasks and procedures are performed.

» The first step is to assign 6S job responsibilities and integrate 6S duties into regular work duties using tools such as:

•          Job cycle charts

•          Visual cues (e.g., signs, placards, display scoreboards)

•            Checklists

» The next step is to prevent:

•          Accumulation of unneeded items

•          Procedures from breaking down

•          Equipment and materials from getting dirty.

Pillar 6: Sustain (Keep it up)

» Makes a habit of properly maintaining correct procedures

» Often the most difficult pillar to implement and achieve

» Sustain focuses on defining a new status quo and standard of workplace organization

» Without the Sustain pillar, the achievements of the other pillars will not last long

» Tools for sustaining 6S include:

•          Signs and posters

•          Newsletters

•          pocket manuals

•          Team and management check-ins

•          Performance reviews

 •         Department tours

    

Benefits of 5S

• Improve safety
• Decrease down time
• Raise employee morale
• Identify problems more quickly
• Develop control through visibility 
• Establish convenient work practices
• Increase product and process quality
• Strengthen employees’ pride in their work
• Promote stronger communication among staff 
• Empower employees to sustain their work area.