5S method: What is this methodology and how is it applied in the industry?

What is the 5S method?

The 5S method is a powerful Lean Manufacturing tool for order and cleanliness applied in production systems and widely used in industrial engineering in general. It is also a mandatory practice in any quality management system.

5S methodology consists of 5 Japanese words that start with the letter S: Seiri, Seiton, Seiso, Seiketsu, and Shitsuke, which can be translated into English as: Sort, Set in order, Shine, Standardize, and Sustain.

What are the 5S and their meanings?

The following table presents the 5S in their Japanese and English definitions, along with a brief explanation of each concept and its objective:

Origins and principles of the 5S method

Seiri: The first step is to Sort

Here, you should continuously question: “What is this for?” “Who needs it?” “How often is it used?”

Specific actions to take during the Sorting phase:

• Place useless items away from the workstation to verify they are indeed useless.
• Remove excess items, “What is unnecessary.” For example, having overstocked parts, personal items.
• Understand why useless items ended up at the workstation. This will prevent the same issue from recurring in the future.

Seiton: Organize to eliminate searches

Here, the questions to answer are: What? Where? How many? and Why?

Specific actions to take during the Organizing phase:

• Follow the principle: “More frequent use = closer proximity.” Place frequently used items near the workstation.
• Accessibility should be determined with the users.
• Follow the premise: “A place for everything, and everything in its place.”

Seiso: Shine

This involves regular cleaning with the additional objective of inspecting equipment and elements.

Specific actions to take during the Cleaning phase:

• If there is a cleaning standard or instruction, review it to avoid a “general cleaning.”
• Identify anomalies, dysfunctions, the source of dirt, and resolve them.
• Create a list of detected anomalies that couldn’t be immediately resolved.

Seiketsu: Standardize

The goal here is to ensure the preservation of the obtained state.

Specific actions to take during the Standardization phase:

• Guidelines, the more visual and evident, the more they are respected.
• Define and explain the standards.
• Check standards that are not adapted or are difficult to apply.
• React: confirm or improve the standards.
• All personnel should know the standards.

Shitsuke: Sustain

Lastly, and most importantly, Shitsuke seeks to involve all participants in respecting the standards and in pursuing continuous improvement.

Specific actions to take during the Discipline phase:

• The culture of respecting the standard is materialized by daily checking for occasional deviations from the standards. Impose and practice SELF-EVALUATION.
• Self-evaluation by each person establishes a REAL measure indicator.
• Why are the standards not respected? Perhaps they need to evolve, or maybe it’s the manifestation of a new anomaly.
• Dare to point out anomalies and consider them for improvement.

How to apply the 5S method in a company?

Below, we break down each of these principles focused on business application. This lean-manufacturing tool is one of the most important pillars of continuous improvement, Kaizen.

Seiri (Sort)

The first step involves eliminating the unnecessary. Identify and remove items that are not essential for daily operations. This includes broken tools, obsolete documents, and unused equipment. Keep only what is essential.

Seiton (Set in Order)

Organize the workspace efficiently. Every item should have a designated place. Clearly label everything for easy identification and ensure objects are placed in an orderly manner to avoid wasting time searching for them.

Seiso (Shine)

Maintain a clean and orderly work environment. Encourage daily cleaning and regular inspections to ensure everything functions correctly. Constant cleaning reduces the risk of accidents and increases efficiency.

Seiketsu (Standardize)

Establish clear standards and procedures for all employees to follow. This ensures practices are consistent and facilitates the training of new employees.

Shitsuke (Sustain)

Encourage discipline and responsibility in the organization to maintain the established standards. Conduct regular audits to verify that the 5S are being followed.

What problems do the 5S method solve?

The 5S address several common problems in the business environment:

• Waste: They help reduce waste of time and resources by eliminating unnecessary items and organizing the workspace efficiently.
• Inefficiency: By optimizing the arrangement of tools and materials, they reduce search time and production errors, increasing operational efficiency.
• Quality: By maintaining a clean and orderly space, early problem detection is facilitated, leading to improved product quality management and workplace safety.
• Employee Motivation: A clean and orderly work environment positively influences employee morale and fosters a more pleasant work atmosphere.

Why implement the 5S method?

Implementing the 5S offers numerous benefits, including:

• Increased Productivity: Reducing time lost searching for tools or materials and improving overall efficiency leads to increased productivity.
• Improved Quality Management: Standardization and regular cleaning help detect quality issues before they become defects in the final product.
• Cost Reduction: By eliminating unnecessary items and avoiding downtime, the 5S help reduce operational costs.
• Improved Workplace Safety: A clean and orderly environment reduces the risk of accidents and improves employee safety.

Conclusions of the 5S method

In summary, the application of the 5S methodology is essential to achieving an efficient, safe, and high-quality work environment. By following the principles of Sort, Set in Order, Shine, Standardize, and Sustain, companies can solve common problems, increase productivity, and reduce operational costs. Implementing the 5S not only benefits the company but also its employees, creating a more pleasant and motivating work environment. If you’re looking to optimize your operations, consider implementing the 5S as a crucial step in your continuous improvement journey.