TOTAL FLOW MANAGEMENT

What is 5S?

5S is an approach originally developed in Japan for better housekeeping. Now it is being utilized for keeping better workplace. It includes 5 steps which are to be followed sequentially. To be precise, 5S is an approach for managing workplace. Following Japanese terms collectively are as called 5S

5S” or "Lean 5S" is a method to promote a safer, cleaner, and better-organized workplace – often a factory, but the 5S method can be applied to almost any work environment:

Office space – from cubicles to mail rooms to library space
Computer or server rooms, including online files and folders as well as physical objects
Work bench areas
Warehouses, storage sheds and outdoors storage areas
Hospitals and health care facilities

What are the 5S?

1S – Seiri – Sorting – calls for the elimination of unnecessary items that have collected around work areas
2S – Seiton – Set in Order – focuses on effective storage and organization methods that resists clutter and aids long-term productivity
3S – Seiso – Shine – focuses on importance of cleaning in workplace with a view of employee health, morale and safety
4S – Seikestu – Standardize - creates a workplace where employees can confidently pursue their daily work with common understanding of the working methods
5S – Shitsuke – Sustain – focuses on self-discipline and methods of sustaining the efforts put in all other S’s to extract maximum effectiveness on regular basis

How to Implement 5S?

Identify a work area to make a Model 5S Workplace
Conduct initial Seiri – identity unwanted – rarely used – frequently used item, and mark them by tagging
Arrange only required work and items in a systematic manner – concept of PEEP (place for everything & everything in place)
Conduct cleaning of the workplace and promote cleaning by workplace users
Standardise activities and workplace through – colour coding, cleaning checklist, standard operating procedure for the workplace
Make the workplace as much visual as possible
Make auditing plan, train operators and workers about the best practices of workplace management
Plan for horizontal deployment in whole factory with reference of the Model Workplace

Direct Benefits of 5S:

Quick retrieval – less time wasted searching for misplaced items
Health and safety – reduces the risk of injuries, in both the short and long term
Lesser Breakdown – cleaner equipment may mean fewer malfunctions or breakdowns
Improved Productivity - standardized workflow results in quicker operations
Improved Morale – workers0 and employees can take greater pride in a clean and orderly workplace

Indirect Benefits of 5S:

Both fewer injuries, and fewer long-term illnesses, lead to a reduction in lost time, compensation, and scrambles to train workers to cover for colleagues
Less time spent searching for misplaced tools or parts means higher productivity
Cleaner equipment may mean less downtime for repairs or maintenance, and also savings on replacement parts
Optimized workflow leads to higher productivity due to time savings
Optimized workflow leads to higher productivity by reducing process errors and re-work
A cleaner workplace may result in cost savings for janitorial staff
Obsolete equipment or parts may be sold
Reduced inventory – whether equipment, spare parts, or raw materials – may result in reduced warehouse costs