5S and the Visual Workplace
The philosophy of continuous improvement is more than a trend in today's business environment, and the solution is the visual workplace - for improving quality, organization, efficiency, housekeeping and safety. Visual tools such as shadow boards and safety signage play a key role in making these improvements visible and sustainable.
The 5S methodology, as described in the 5 Pillars of the Visual Workplace, is the foundation for making company-wide improvements in both the production facility and the front office, so that the just-in-time production strategy (inventory management) can be implemented.
The 5S's are based on the Japanese words seiri, seiton, seiso, seiketsu and shitsuke, and, when transliterated, mean organization (sorting), orderliness (setting in order), cleanliness (shining and sweeping), standardizing (standardized cleanup)and discipline (sustaining the process). These 5S's are the basic formula for achieving "product diversification with zero change-overs, higher quality with zero defects, lower costs with zero waste, and reliable deliveries with zero breakdowns and improved safety with zero injuries."
A sixth "S", "Safety", is sometimes added depending on the workplace, and some argue that explicitly including this sixth "S" ensures that workplace safety is given primary consideration. But it is reasonable to assume that a properly planned and executed 5S program will inherently improve workplace safety.
Sorting
The main component of the first "S" or sorting phase is ridding a bloated production facility of any unwanted, un-needed or unused tools or materials. This happens by implementing the "Red Tag Strategy" - applying a red tag to anything considered unnecessary in a production cycle, placing in a holding area to see if it was needed, and then ultimately discarding anything not needed; "When in doubt, throw it out." Red tagging works best when paired with visual organization systems that maintain order after unnecessary items are removed.
Products associated with sorting and the red tag strategy includes Red Tags By-The-Roll and Red Tag Area signs.
Setting in Order
A lot like a home garage peg-board, or a surgeon's tray of instruments, the second "S" gives each tool a permanent place to reside so that whether the employee is new or temporary, they know exactly where to find it and return it when finished. Visual systems like shadow boards make tool placement clear and help identify missing items immediately.
Products associated with setting in order include 5S shadow boards, such as Accuform Store-Boards™.
Shining
When the work area is clean and maintained, maintenance and repairs can happen instantaneously, because they come to a worker's attention immediately. In a dirty environment, machines that could be easily fixed may break down because an oil drip was not noticed until it was too late.
Standardized Cleanup
Once everything is in its place and the work environment is clean, don't stop there. Determine daily (even shift) targets, assignments, methods, tools - then keep going. There is no limit to how often, how long, what procedure or what tools to use, until it is determined that once your daily cleaning duties are accomplished, your time can be better spent elsewhere.
Products often associated with standardization include Site-Boards™ and visual workplace systems that reinforce consistent organization.
Sustain the Discipline
Simply put, "Make a habit of properly maintaining the correct procedures." Without discipline, excess materials are purchased because they're not in the proper place, workers waste time searching for misplaced tools, the facility will get dirty again causing machines to break down, and accidents will become more prevalent. Visual tools like shadow boards help reinforce these habits by making it immediately clear when items are out of place.
Build a More Effective Visual Workplace
Implementing 5S is easier with the right visual tools in place. Solutions like shadow boards, red tags and visual management systems help maintain organization, improve efficiency and support long-term workplace safety.
Explore Accuform visual workplace solutions to support your 5S program.
Store-BoardsTM
Store-Boards™ Shadow Boards offer the ultimate in customization to meet your specific 5S tool and equipment storage needs.
Site-BoardsTM
Site-Boards™ are visible wall displays that effectively communicate, control, convey, organize, and track production, quality, and personnel information.
