Create a visual workplace using 5S principles

Posted by Steve Gohde on January 25

The 5S system (Sort, Straighten, Shine, Standardize, and Sustain) is designed to organize a work space in the most efficient and effective means possible by identifying, using, and storing items in a manner uniformly understood and adhered to by all team members. 5S is easier to implement than it sounds and when done properly, can increase worker productivity, reduce costs associated with loss and breakage, and create an overall safer work environment. The following are explanations of each “S” as well as examples on how to implement 5S in a simple and cost effective way.

Sort: The goal of sorting is to get rid of all unnecessary tools and equipment in a workplace. Forinstance, if a particular workstation is designated for repair of a particular part, only the tools, materials, and instructions associated with that particular activity should be in that workspace. Additionally, an easy way to identify if something is out of place is by using color coded labels on tools. As an example, if Workstation 1 has all blue labels on the tools labeled “Workstation 1” and if Workstation 2 has all green labels on the tools labeled “Workstation 2”, a quick visual scan of the tools at the workstation would show if a tool were out of place.

Straighten: Straightening within a workspace means that all tools and equipment have a clearly marked “home”. A tool’s home is the location that the tool should be stored in when not in use. Each home should support the most efficient flow of work possible, ease the strain of accessing and utilizing the tool, and be located within reach of the job at hand. The easiest and most effective way of creating a home for each tool is by both creating a clear outline for where a tool should reside as well as a label that can be tied to the label on the tool itself. By giving tools a home location number and placing that same location number on the tool with a label, one can ensure that any team member can easily identify and return tools to their respective homes.

Shine: Clean tools, equipment, and work areas are safer and more effective. Creating a defined time to clean up an area, as well as replace labels that aid in Sorting and Straightening, is important to maintaining a 5S implementation. It may be at the end of a shift, while a piece of equipment is down, or after each job, but when done at regular intervals throughout the day, this not only keeps everything in place, but also makes it is easier to identify problems quickly. As an example, were a spill seen in an area that is normally clean and dry, it would be easier to identify an issue and fix the problem. Quick identification of the spill can help to reduce the risk of injury or exposure to hazardous chemicals. As always, when working with hazardous substances it is important to clearly identify potentially hazardous materials with warning/signal words on labels/signage in colors that adhere to OSHA, ANSI, and ISO visual workplace standards.

Standardizing: Creating consistent workflows, easily understood processes, and replicating workstation layouts for similar tasks is key to creating a standardized workplace. This allows for employees to be easily moved between different workstations without losing productivity. Ensuring that each employee has been trained on the job to be executed, as well as the responsibilities of maintaining each work area will ensure that the 5S regimen remains effective over time.

Sustaining: Sustaining refers to training and reinforcing the responsibilities associated with Sorting, Straightening, Systematic Cleaning, and Standardizing.  It is important to consider implementing regular audits to ensure that the system is being adhered to, and to provide employees with an opportunity to provide input on ways to further improve the 5S in your work space.

 

---