| Japanese | English | Viet Namese | |
|---|---|---|---|
| S1 | Seiri | Sort | Sàng lọc |
| S2 | Seiton | Set in Order | Sắp xếp |
| S3 | Seiso | Shine | Sạch sẽ |
| S4 | Seiketsu | Standardise | Săn sóc |
| S5 | Shitsuke | Sustain | Sẵn sang |
5S
In the Introduction to 5S we met the five steps and discoverd their names in Japanese, English and Vietnamese. Let’s remind ourselves óf what they are with another look at those words.
Following, I will give you an idea on how a successfully implemention of the 5S methodology will effect your efficiency. This will not be extensive as every situation in different workplaces will have many variations to look at and discover. However, an experienced 5S consultant can recognize these differences fairly quickly and assist greatly in the implementation. Like all thing in life and business, good preparation is vital.
We Want to Create a World Class Environment
Why a World Class Environment
To Create
The correct mindset for all employees
A sense of pride in the workplace
Motivation in the workplace
To Improve
Efficiency
Performance visibility
Profitability
To Gain
A competitive advantage
Customer and regulatory compliance
An error free workplace
In our everyday life, in our employment and in our social life, we all tend to retain items needlessly and not discard enough, of all manner of things, we do not use anymore. Whether you are that hoarder, have sentimental feelings towards inanimate items or have been instructed by others not to throw things away, we all keep useless items that just take up space, valuable space especially when you are paying rent on it.
“It’ll come in handy one day” is a phrase we have all uttered. In fact, most of that junk, and yes it is junk, will never play a useful role in our lives ever again.
Left over pizza that will taste great for breakfast in the morning?
That pair of footy boots we kicked 4 goals in one day.
The bridesmaid dress that we wore to our former BFF wedding.
The screw driver that has half its tip missing.
THEY ALL NEED TO GO!
But firstly, you need All Employee’s to “buy into” the idea of introducing 5S.
You need to have a strong Management Team in place when you seek employee “buy in” to the implementation of the 5S methodology at your company or with your wife and/or family if you wish to better organise around the home. This is essential, prior to any discussions with the employees’. However, we are warning you that, some people in your Management Team maybe the largest stumbling blocks in the entire process of firstly introducing the concepts of 5S and then implementing the methodology.
The current system is “their” system and they will be the ones that resist change vehemently and 5S is a major change. If you have a recalcitrant manager, cut the snake off at the head. Ditch them completely. If you, as the owner of the company or in your role of CEO think change needs to be made, you will not succeed with one person at a Senior level not being committed to the project.
Sort - S1
How do we Sort?
Remove all items not needed for current production or operations.
Leave only the bare essentials: “When in doubt, throw it out”. Use the 30 day Rule, if something has not been used in the previous 30 days consider removing it from the workplace .
We will place a Red Tag on these items to identify them.
Why do we Sort?
Space, time, money, energy and Human Resources can be managed and used more productively.
We reduce bottlenecks in our work flow.
It improves communication between workers and workers and management.
It raises product quality.
It increases productivity, we will not be busy, we will be productive.
It gives us back valuable floor space.
And all this Sorting is for greater profitability
We Sort to Avoid
Our workplace becoming increasingly crowded, dirty and disorganised.
Unneeded items getting in the way of quality production flow.
Time wasted searching for tools and other equipment.
Unneeded inventory.
Excess stock hiding production problems and defects.
Unneeded items and equipment making it harder to improve the process flow.
Busyness
Set in Order - S2
“A place for everything and everything in its place”, is how myself and many other 5S professionals best like to describe the second part of the 5S methodology, S2 Set in Order.
We want to keep items and work flow in an organised way.
How do we Set In Order?
We arrange required items so that they are easy to locate & easy to use.
We label items so that anyone can find them and/or put them away.
We arrange purchases such as shadow boards to enable the above.
We purchase the correct tools and equipment to enable work to be carried our productively and not be busy.
Why do we Set In Order?
• To eliminate many kinds of waste, including:
• Searching waste.
• Waste due to difficulty in finding items.
• Waste due to difficulty in using items.
• Waste due to difficulty in returning items.
Overall reducing busyness and replacing it with productive methods
We Set In Order to avoid.
• Motion waste.
• Searching waste.
• Waste of human energy.
• Waste of excess inventory.
• Waste found by defective products.
• Waste found in unsafe conditions
We Set In Order to avoid.
Wasted motion.
Time waste.
The waste of human energy.
The waste of paying for and storing excess inventory.
The waste caused by producing defective products.
The time waste caused by re-working defective products.
The waste caused by working in unsafe and inappropriate conditions
Shine - S3
There are many business owners, Chief Executives Officers and General Managers who, when they first read, hear or are told about 5S, concentrate solely on S3, Shine. They feel that all the problems that they see in the production facility will be solved by having a Spring clean. I am a real big fan of having a very clean work place wherever you work. However, as we will discover, we can make the Shine process easier to complete and easier to maintain on an ongoing basis because it must be maintained, in fact, we will do better than maintain the cleanliness achieved through Shine, we will adopt Continuous Improvement and get better at keeping the work place and equipement available and that will give everyone a better feeling to work their best by taking pride in their work place. It will not be a chore in itself just getting to work each day.
How do we Shine?
We keep everything, every day, swept, brushed and clean
Why do we Shine?
We Shine to turn the work place into a clean, bright place where everyone will enjoy working
To keep everything in a condition so it is ready to be used when required
We Shine to avoid
A lack of sunshine and fresh air that can lead to a lack of morale and inefficient work practices
Hidden and hard to detect defects
A dangerous work place caused by lack of cleaning with health and safety hazards in large numbers
Our machines, tools and equipment not receiving the maintenance and attention they need to operate at their capacity. Machines not receiving maintenance, break down, causing more defects and production down time.
S4 - Standardise
Some International standards that make life easier for all are braille, the International Maritime Signal Flags, A4 (and other) paper sizes and the Hazard symbol. See it, know what is means and use it all of the time.
Companies all over the world strive to be granted certification from the International Organisation for Standards which strangely for an organisation all about standards has the acronym ISO. If we strive to recognise an international standard we should also strive to develop, implement and maintain our own company standards and our own personal standards.
The importance of standards has been known for a long time with the following quote being one of the pieces of knowledge I attempt to have everyone in an organisation understand,
"The standard you walk past is the standard you accept. If that does not suit you then get out"
- Lieutenant-General David Morrison
It emphasises that Leaders set the tone for acceptable behavior and performance in their organizations. It suggests that inaction or tolerance of poor standards signals acceptance of those standards to others.
How do we Standardise?
We integrate Sort, Set in Order and Shine. We create a unified “whole”.
Why do we Standardise?
To ensure conditions do not deteriorate to their former state and to create the unified “whole” from the succesful first three S’s.
To not waste the efforts from the first three S’s implementation
So that everyone can immediately rcognise when somethng is amiss. Our workplace becomes “visual”.
We Standardise To Avoid
Conditions returning to the their old, undesirable levels.
Work areas becoming dirty and cluttered.
Tool storage becoming disorganised.
Clutter again accumulating over time.
Backslide occurring and becoming busy.
These standards that we will establish should ensure that the work we have performed by implementing the first three steps of the 5S methodology are repeated (and repeated) again and again as well as being improved upon by staying alert to Continuous Improvement.
S5 - Sustain
As we have stated, having an organised work place such as we have demonstrated here, can “Quality Control” our work place. Furthermore, we have empowered every worker and every Manager from Owners and CEO’s down to observe the work place continually, soak in the improvements but also be the most important person the the room, our work place 5S Quality Controller. This is how we Sustain.
How Do We Sustain
By making it a habit to properly maintain the correct procedures.
To place the discipline necessary inside everyone’s head to avoid backsliding.
Why Do We Sustain
Because the consequences of not keeping to the course of action we have undertaken is greater than the consequences of adhering to it.
We Sustain to Avoid
Tools and jigs not getting returned to their designate “home”.
Unneeded items piling up
No matter how dirty and equipment and workplace becomes, nothing is done to clean it.
Equipement and tools being left in hazardous positions.
A loss of worker morale by having to work in a dark, dirty and disorganised workplace.
Our workplace becoming busy rather than becoming productive.