Workplace Organization
Benefits of lean manufacturing cannot succeed in a workplace that is cluttered, disorganized, or dirty. Poor workplace conditions lead to wastes such as extra motion to avoid obstacles, time spent searching for things, and delays due to defects, machine failures, or accidents. Establishing basic workplace conditions is an essential first step in creating a manufacturing cell. In many companies, employee teams use the 5S system to improve and standardize workplace conditions for safe and effective operation.
The 5S philosophy focuses on simplifying the work environment, reducing waste, and improving quality and safety.
The 5S system includes: Sorting/Eliminating materials that do not belong in the work area (Seiri). Sorting is an excellent way
to free up valuable floor space and eliminate such things as broken tools, obsolete jigs and fixtures,
scrap, and excess raw material.
Storage/Eliminating time wasted looking for things, creating logical storage (Seiton) Strategies
for effective Storage are painting floors, outlining work areas and locations, shadow boards, and
modular shelving and cabinets for needed items such as trash cans, brooms, mop and buckets. "
A place for everything and everything in its place."
Shining/Cleaning religiously ?clean for grime and inspect while you're cleaning (Seiso). Once you
have eliminated the clutter and junk that has been clogging your work areas and identified and
located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up
cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and
clutter-free work area and the "Shining" step will help create ownership in the equipment and facility.
Standardizing/Make all work areas the same, so procedures and abnormalities are obvious
(Seiketsu). Once the first three "S's" have been implemented, you should concentrate on
standardizing best practices in your work area. Allow employees to participate in the development
of such standards. They are a valuable but often overlooked source of information regarding
their work.
Sustaining/Internalize the rules and make them habits (Shitsuke). This by far is the most difficult
"S" to implement and achieve. Human nature is to resist change and more than a few organizations
have found themselves with a dirty cluttered shop a few months following their attempts to
implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way"
of doing things. Sustaining focuses on defining a new status quo and standard of work place
organization.
Once fully implemented, the 5S system can increase moral, create positive
impressions on customers, and increase efficiency and organization. Not only will employees feel
better about where they work, the effect on continuous improvement can lead to less waste, better
quality and faster lead times. Any of which will make your organization more profitable and
competitive in the marketplace.
Depending on your individual situation, 5S systems can be implemented in different ways. Many follow a procedure similar to the following:
Organize the program committee
Develop a plan for each "S"
Publicly announce the program
Provide training and education to employees
Select a day when everybody cleans up and organizes their working area
Evaluate the results of 5S
Take corrective actions
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