5S Training and Implementation
5S is a Lean Manufacturing system of techniques that reduce clutter in a workspace. 5s is also called visual management because of its usage of color coding, labeling and checklists. Lean Manufacturing concepts and techniques all have the same focus: a basic and simple rule set to streamline a workspace and work flow into a lean organization. On paper 5S evaluation and implementation looks easy. However 5S can get rather complicated if proper attention to detail is not used in all 5 Pillars along with proper training and cooperation of all employees. Our consultants knowledge of evaluation, implementation and training of 5S will incorporate it into your facility smoothly. We also stay on working with your employees to ensure it is sustained as a ongoing process of continuous improvement.
The 5 Pillars of 5S
1. Sort
Organizing the work space is important. We identify the key items and tools needed within a workspace based upon usage. This is done to simplify the daily routine for your employees by locating frequently used items within their work space and clearing the workspace so time is not wasted with unnecessary searching. Less frequently used items are stored in easily accessible areas for when they are needed.
2. Set
Once we have completed the first stage of 5S we now designate a specific area for every item and tool. We have knowledge of different storage techniques and systems in order to chose the best match for your facilities needs. We also make use of signs and labels in order to help your employee’s learn the new system and use it.
3. Shine
Clean and bright work areas not only help your employees find tools and other related work items more efficiently, they also make it easier reduce safety and health issues. When cleaning is part of the daily or per shift process it also helps employees perform maintenance in areas that might be overlooked otherwise. Cleaning also speeds up productivity due to tools and equipment always in a state of readiness for immediate use.
4. Standardization
This is where processes for sort, set, and shine need to be determined and who will be responsible need to be clearly outlined. Employee training in the methods and processes for applying 5S techniques and maintaining is required to ensure usage by management and employees.
5. Sustain
The final 5S pillar is more than monitor and refine, it is indoctrinating the entire system into your corporate culture. Sustain is the hardest stage because it is easy to allow new processes and policies revert back to old habits. This is done by educating your employees on the techniques and the concepts. Communicating to your employees on why the system is being used and how it benefits them. Recognizing achievements and rewarding them. Soliciting ideas for improvement empowers employees and encourages sustaining the system. Time needs to be specifically set aside for tasks required, a clear definition of responsibilities and checklist schedules that are updated as tasks are completed.
Benefits of implementing 5S Lean manufacturing techniques within your organization:
- Reduced set-up times
- Reduced change-over times
- Reduced cycle times
- Increased floor space
- Lower accident rate / safety concerns
- Less wasted labor
- Increased equipment reliability
- Overall better facility maintenance
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