Implementation of 5S in an organization usually involves the following steps
- 5S implementation team formation
- Waste identification
- 5S manual and process details are developed
- Training and orientation of employees
- Implement 5S
- Measure the progress and feedback on implemented sub-processes
- Continuously improve and refine
The 5S implementation process usually initiates with taking pictures of the present setup to photograph, the faults and shortages for easy observation of the points to take notice.
Next, arranging meetings with the workers on listed faults and targets to achieve are conducted. Discussions focus on identifying the necessary and useful and what was useless. Employees themselves list tools and equipments frequently needed by them and what are not needed which is also examined to prevent any exaggeration like tools needed more than once a week might be missing as the company had only a few of them. Workers shared their knowledge which is very difficult to observe.
Implementing the 5S phases can be summarized as
The first phase, starts by gathering everything unnecessary, rarely used and disposable equipments or materials from the workstations. Tools, accessories and other, which should not be there was gathered on specific locations nearby. The “red tag”-materials should be sorted in groups immediately so it is easier to move those forward.
Second phase of the 5S is usually the hardest as many parts and tools are in wrong and bad locations and tools are often mixed up between workstations due to borrowing-culture amongst them. Measuring devices which are mostly used should be placed on place where everyone can find them when needed. Mark drawers with name stickers to easily identify the materials, tools and other things. New storage spaces should be planned for better organization, if needed. Marking and placing tools, tool racks and tool cabinets with colorful cable ties helps in prevention of them getting lost or mixed up.
Cleaning and sorting up the places is not a huge task and cleaning of metallic dust, oil or cutting fluids is to be undertaken to begin with. Benches, work surfaces and closets should be cleaned and floor should also be washed along with passages and the areas for the pallets drawn with yellow and black-and-yellow marking tapes on the floor. Rooms for the storing cylinders should be cleaned carefully with specified chemicals to remove rust and dirt. Different kind of signs and plates, like place for the truck and incoming and outgoing goods should also be installed.
Next phase involved creation of a standard work instruction to be followed by the employees which lists tasks to be done and when. The tasks should be divided as per frequency like daily, weekly and monthly actions to highlight important tasks. This phase aims for specifying the segmentation of responsibilities and work assignments. Standard work instruction gives needed directives so that cleanliness and order are going to be maintained continuously.
With standardization it was also possible to make 5S-results visible and by that way to give more motivation for the employees. A problem was that it is really easy to accomplish this system once, but without standardization it is a lot easier to get back to earlier types of actions. With shop floor the tools in each post, dustbins empting intervals, cleaning schedule and the places for the passages were standardized. Audits are also conducted for keeping the achieved goals.
Sustain is going to be success only if everyone acquires the operational principles and methods. It means that every person should commit themselves for sustenance and development and also know their responsibilities. Workers took this immediately for themselves and concerned if someone was breaking the standards or agreed working methods.
