Benefits of 5S: Is Lean 5S just Housekeeping?
Lean Manufacturing 5S
What are the benefits of 5S implemented as part of Lean Manufacturing? Many people mistakenly believe that 5S is just housekeeping, but it is far more than that by a long way.
If you could improve the efficiency of your production area by 10%, would you do it? Simple reorganization of your workplace could achieve this or much more. Well 5S can help you achieve efficiency improvements in some environments by as much as 30% or even more!
5S is a basic building block of lean manufacturing and provides a solid foundation upon which to build future improvements within your business. The benefits of lean manufacturing can only be realized through implementing the full philosophy of "lean" and the various lean tools.
5S is a very inexpensive tool to implement. If your team is coming up with highly expensive proposals for 5S implementation then they are probably not thinking hard enough about your problems. 5S is not just applicable to the factory floor; the principles of 5S can be applied in any setting or application. You can apply 5S in the office, even to the files on your computer hard drive.
The benefits of 5S are very significant when compared to the relatively inexpensive and simple implementation process.
Origins of 5S
The history of 5S within Toyota is not as clear as for some tools and seems to be fairly confused, some attributing it to Toyota and others to the Japanese Plant Maintenance Institute. Whatever the specific origins are it is clearly part of TPM (Total Productive Maintenance) and has been well absorbed into the Toyota Production System (TPS) and lean manufacturing.
However 5S clearly reflects the original Ford tool CANDO system:
- Cleaning up
- Ongoing Improvement
So i would suggest that as Toyota based much of their original learning on what they bought from Ford on their various visits, 5S may be a derivative of the Ford CANDO system.
5S BenefitsClick thumbnail to view full-size
Steps of 5S
The following are the Japanese and English names for the main steps of 5S with a brief explanation.
1. Seiri, or Sort
Remove all unnecessary clutter from the workplace leaving only the necessary items.
2. Seiton, or Set in order
Arrange all items visually for ease of use and retrieval. Also to allow missing items and shortages to be identified rapidly.
3. Seiso, or Shine & Check
Clean (and keep clean) the workplace so that problems can be identified when they occur.
4. Seiketsu, or Standardise
Make the first three steps part of the everyday routine with regular audits and so on.
5. Shitsuke, or Sustain
Create a culture with a shared set of values that maintains all of the above.
And some organisations add a 6th S:
Ensure the safety of your employees through the implementation of the first five steps.
Benefits of 5S
5S has many benefits as part of lean manufacturing. Improvements in the order or 10 to 30% in manufacturing efficiency can be gained through implementing 5S. This is certainly true in my experience. Having run many projects in a variety of industries I have seen improvements in these orders in every project, even in those companies that prided themselves on their housekeeping.
Typically the benefits of 5S will cover the following areas:
Efficiency improved due to the removal of clutter and the highly organized ergonomic workspace that is created through the application of 5S.
Delays reduced due to more visible workspace organization, missing tools and components immediately obvious. Problems are immediately obvious as they will tend to manifest as things being placed where they do not belong, thus driving people to fix them quicker.
Setups reduced due to ergonomic layout and organization of tools and equipment in a clearly labeled and highly visible manner.
Improved Morale and Staff Involvement
Morale improved due to the employees' involvement in improving their own workspace for their own benefit making their work easier and less stressful. Remember, lean is not about turning people into robots.
Marketing help due to the tidy and organized layout resulting from your implementation of 5S.
Improved Quality Performance
Quality improved due to standardized ways of working and basic maintenance of tools and machines. The correct tools and equipment being in place means that the right tools are used for the job, plus the ergonomic workplace reduces opportunities for handling damage and the like.
Reduced Energy Costs
Energy savings due to increased efficiencies.
Safety improvements due to the removal of clutter that creates hazards. “A place for everything and everything in its place." An ergonomic layout that prevents stressful and “dangerous” movements such as removing heavy objects from high or low locations.
Inexpensive to Implement
Should you invest in a multimillion dollar machine to gain an extra 10% improvement in efficiency, or do a methodical reorganization of your workplace that will cost you only the time taken to do it? The gains made by implementing 5S will cost you next to nothing especially when compared to other initiatives.
5S Continuous Lean Improvement
Implementing 5S to Gain Benefits
5S lean is best implemented under the guidance of an expert, either your experienced internal lean practitioner or a lean trainer or consultant hired to provide in-house 5S training.
5S is a team-based approach that requires the involvement of everyone in the specific area being improved, as well as involving people from outside the area for additional ideas. 5S is very much a hands-on tool; all those involved should expect to be involved in every aspect of the implementation, from clearing out the clutter to cleaning, audits, and continual improvement.
5S is not a once-off activity. The organization should encourage continual improvement of the workplace and promote a lack of tolerance for things that are not to standard.
5S Builds a Firm Foundation for All Other Improvements
5S does not just tidy your work environment as you would do for the visit of the chairman of the board or some other local dignitary. It is an ongoing and sustained improvement in how your organize your work place.
But one of the most important parts of 5S is that of standardizing your work (the 4th step of 5S - Seiketsu). Standardization provides you with that firm foundation on which all other improvements can be built. Until you have a repeatable and stable process, you have no idea what is causing your problems and no way to ensure that improvements will either make a difference or even remain effective.
Simple documents to define how work should be performed (Standard Operating Procedures (SOPs) or Work Instructions) can be created very simply using standard word processing packages and digital pictures ensuring that everyone knows exactly the best method for conducting an operation. This will reduce differences between shifts and different operators as well as giving something that can be improved on.