5S Implementation Strategies
5S implementation is one of the smartest things you can do for your business, without a doubt. The old junk will be gone, every single thing in your shop will have a home, and the entire crew will be happier and more productive. Who could want more?!
sincerely, if you have not made 5S implementation part of your daily operation, get started now. There is really no reason to delay, unless you are already highly organized and efficient. It could be that some exceptional manufacturing shop is just naturally that way, it does happen, but rarely.
There are obviously 5 parts to the program: Sort, Straighten, Sweep, Standardize and Sustain. Of all the lean programs, 5S will bring the quickest and most dramatic results; it is impressive to watch.
What are the components of 5S Implementation?
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Sort
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Straighten
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Sweep
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Standardize
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Sustain
The first time I was part of a 5S training program was with a typical American plastic injection molding shop with about 10 mold makers. Ever since plastic was a viable business, our company had been involved, so there was a lot of ” stuff” laying around. It seemed that everything had a place, but only a few knew the secrets of where it all was.
I was very doubtful of this programconcept at first because I had spun my wheels for so long on every new program that the management learned at the latest seminar. So, we just figured 5S was another well-intentioned, but useless idea imposed by out-of-touch managers.
The fact that is was Japanese managed to get my attention though. At the time, they were conquering our auto industry so I thought they must know something we didn’t.
How to begin with 5S?
This is one of the beauties of 5S: you need very little to get started. Once you master the method, it is a matter of educating your workers to understand the benefits and making it a part of your company culture. The leadership on every level must stand behind the decision to implement 5S, otherwise it is sure to fail.
Does 5S take a long time?
Our mold making shop needed about a week to actually complete the process. progress], but it was essential that we completely finish the project. I’m certain that things would have reverted to the old ways if we had not followed all five steps. Changing a company culture is very challenging, but it is possible.
Some of the most resistant employees became staunch allies to the cause, once the results became obvious movers and shakers you need to recruit. In the end, it is very much worth the time and energy, in every way.
The time spent with 5S implementation will most certainly pay for itself in a short time. If you only added up the hours spent searching for tools, etc, you would quickly justify the expense; not to mention the satisfaction you feel from working in a well-organized and orderly environment.
5S is just one part of the lean manufacturing process. It is also essential that everyone follows through, so the benefits can be permanent. Take pains to lay a solid foundation by mastering the basics.
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