5S is a Lean tool and a step-by-step plan for a tidy workplace, to reduce waste on the shop floor. It brings overview, calm and structure. The five S’s stand for Sort, Set in order, Shine, Standardise and Sustain.
The plan aims for the following:
- only the materials and machines that are really needed are on the shop floor;
- the workplace is clean and safe;
- all materials have a fixed place;
- you see at once when something is missing.
This is one of the tools you learn to apply in the Green Belt training.
Origin of 5S
5S comes from Japan, where the S’s stand for Seiri (sort), Seiton (set in order), Seiso (shine), Seiketsu (standardise) and Shitsuke (sustain, also translated as discipline).
Why 5S?
Untidiness can lead to accidents. Equipment lying around creates tripping hazards, and water or grease stains create a risk of slipping. On top of that, employees often spend time searching for materials or information, and that is waste.
You carry out the plan together with the people on the shop floor.
The 5S step-by-step plan
S1: Sort
Get rid of what you don’t need in the workplace. Broken or damaged items, things that haven’t been used for a long time and unsafe items are removed. A rule of thumb: if you don’t use something every week, remove it or store it elsewhere.
S2: Set in order
Rearrange the space and think carefully about the right, fixed place for every material.
- Need something often? Put it at eye level and make it easy to reach.
- Keep everything you need for one task together.
- Don’t store heavy items too high, or too low.
S3: Shine
A clean and tidy environment invites people to keep it that way. While cleaning, check whether equipment still works properly: cleaning is also inspecting.
Shine also means removing the causes of breakdowns and contamination, recording cleaning methods, and agreeing responsibilities and standards. It improves safety and reduces the risk of defects.
S4: Standardise
Standardising makes the first three steps last: everyone works the same way. You do this by making the best way of working visible, so every employee can follow it. Visual aids, such as floor markings or a shadow board with the outlines of the tools, keep the chance of deviating as small as possible.
Standardising leads to fixed routines and habits. To work, it has to be short and simple, and visual where possible, with colours or lines. Standardised procedures keep surprises to a minimum.
S5: Sustain
This is the hardest S. It is about lasting attention to improvement: secure the new standard so you don’t slip back into old habits.
The key aspects are:
- encouraging and maintaining discipline;
- training new and experienced staff;
- agreeing the desired level;
- repeating S1 to S4 regularly;
- carrying out regular audits.
Benefits of 5S
Applying 5S brings benefits such as:
- a clean, safe and orderly workplace;
- less waste, such as searching and walking;
- less space needed;
- more self-discipline;
- more satisfied employees.
The main challenge of 5S is discipline: people need time to practise it and to keep their workplace in order.
Want to get started? Use our free 5S tool to run a 5S audit of your own workplace.