The Magic behind the 5S System: Learn How to Apply It in Just 5 Steps

 5S System | Implementation steps

5S System | Implementation steps. 5S is an improvement process to eliminate the waste that originates from a poorly organized workplace/area.. It is the first basic tool and foundation stone of Lean manufacturing and an organization cannot succeed without it.

Importance of 5S System in Sheet Metal Industry
The 5S system is a set of principles and practices that aim to improve workplace organization, efficiency, and safety. The term "5S" stands for five Japanese words: Seiri (Sort), Seiton (Set in order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain).

The 5S system is widely used in many industries, including the sheet metal industry, to enhance productivity, quality, and safety.

Here are some reasons why the 5S system is important in the sheet metal industry:
Improves Safety: In the sheet metal industry, employees often work with heavy machinery and equipment, which can be dangerous if not properly maintained and organized. The 5S system helps to identify and eliminate potential safety hazards in the workplace, such as cluttered work areas, slippery floors, and unsecured tools and equipment.
Increases Efficiency: The 5S system helps to optimize workflow and reduce waste by organizing workspace and ensuring that tools and materials are easily accessible. This can lead to faster production times, improved quality, and lower costs.

Enhances Quality: 

The 5S system promotes a culture of continuous improvement and attention to detail. By implementing standardized procedures and maintaining a clean and organized workplace, sheet metal manufacturers can ensure that their products meet or exceed customer expectations.
Reduces Costs: By reducing waste, improving efficiency, and enhancing quality, the 5S system can help sheet metal manufacturers to lower costs and increase profitability.

Boosts Employee Morale:

 The 5S system promotes a sense of ownership and pride in the workplace. When employees are involved in the process of organizing and maintaining their workspace, they are more likely to feel engaged and motivated.
Overall, the 5S system is an important tool for sheet metal manufacturers who want to improve safety, efficiency, quality, and profitability. By implementing the 5S principles and continuously monitoring and improving their processes, sheet metal manufacturers can stay competitive in an increasingly challenging marketplace.

The 5S technique is not just for manufacturing industries, it is also widely applied in service sectors, hospitals, homes, and offices.

It is a systematic approach to Organization Improvement.

5S formed with the first letter of Japanese words-Seiri, Seiton, Seiso, Seiketsu, and Shitsuke.
5S System implementation steps

Seirior Sorting out
Seitonor Set in Order or Organize
Seisoor Shine or Sweep
Seiketsuor Standardize
Shitsukeor Sustain or Self Discipline

We get 6S with the addition of Safety as an additional “S”. Safety is essential at the workplace, therefore, you can also add Safety to make it a more specific and mandatory step of the 5S implementation process.

5S Meaning | 5S full form in Japanese with English language

5S System | Implementation Steps 

1S: Seiri – Sorting Out

1S Meaning

It helps to segregate necessary & unnecessary items and eliminates unwanted items.

It essentially means organizing/putting things in order

1S Activity or Action to be taken

Segregate Wanted and Unwanted items from the work area/place.

Remove Unwanted ones.

1S Benefits or Success Indicators

Space Saving.

Fastest access for required items.

Improvement in Work Efficiency.

Disposed items reduced your inventory.

2S: Seiton – Set in Order – Organize – Systematic Arrangement

2S Meaning

This step essentially means arranging items in a systematic way, for easy accessibility and using them in the best order.

2S Activity or Action to be taken

Decide the place and Set things in order.

Put everything in its place.

Keep accessibility as easy as possible.

Keep heavy items on the ground floor nearer to entry.

2S Benefits or Success Indicators

Search time reduced.

Time saved in handling material.

3S: Seiso – Shine – Sweep

3S Meaning

Shine everything-cleaning.

This step makes the workplace neat & clean by eliminating dirt, dust & other foreign matter.

3S Activity or Action to be taken

Clean your m/c, tools, equipment, jig/fixture, work table, rack, records, shop floor, etc.

Keep the workplace spotless and make it easy to clean.

Make it easy to find out/Inspect abnormalities.

3S Benefits or Success Indicators

Healthy work environment.

Abnormalities are clearly visible and easily corrected.

Reduction in m/c breakdown/downtime.

Accidents reduction, Safe workplace.

Quality Improvement and Rejection reduction.

4S: Seiketsu – Standardization

4S Meaning

This step is a combination of Seiri, Seiton, and Seiso as an ongoing activity to maintain a clean, safe, and well-organized workplace.

4S Activity or Action to be taken

Put in place standard procedures for all activities.

Make a system to review Standard Operating Procedures-SOPs and Work Instruction-WIs at a defined fixed interval.

4S Benefits or Success Indicators

Improved Productivity and Quality.

Problems are exposed easily and solved.

Reduced Costs.

5S: Shitsuke – Sustain – Self Discipline

5S Meaning

Self Discipline.

This step is to ensure that everyone must adhere to the rules and makes it a habit.

5S Activity or Action to be taken

Fix responsibilities for implementing and evaluating systems/standards.

Make a Self Discipline to follow the set standards.

Regular Training and updates to everyone about “4S.”

Forming Habit/Culture.

Check how well the system/set standards are working and sustaining itself.

5S Benefits or Success Indicators

Total Employee Involvement-TEI.

The habit of doing it Right First Time and Every Time.

Higher Employee Satisfaction level.

What are Unwanted Items/things?

Machine, Tools, Jig/Fixture, Measuring devices

Damage tools, Inserts/bits, etc.

Old/damaged Measuring and inspection equipment not being used.

Old/damaged jigs and fixtures not in use.

Old/damaged machine not in use or operational.

Passages, Pillars and Corners

Junk, dust, and material not required accumulated in corners and besides pillars.

Rack, Shelves, and Lockers

Old/Outdated and damaged records/things gathered that nobody ever uses.

Walls and Boards

Outdated/damaged display boards/notices/posters.

Damage and dirty walls.

Tape gum marks on mirror/wall/door/boards.

Work in Process (WIP) parts

Rework or Repaired items accumulated over a period of time.

Parts/things fallen below or behind the machine.

Excess WIP.

Rejection accumulated and not cleared timely.

Material lying for disposal decision. 

5S Benefits

Cleaner, friendly, Hygienic and better organized workplace.

Shop floor operations become safer and easier.

Improved Quality and Productivity of the Organisation.

Results and problem are clearly visible to everyone.

Visible results enhance generation of more new kaizen/ideas.

Increased Total Employee Involvement-TEI and Satisfaction level.

Reduced Quality and Productivity Cost.

Enhanced organization reputation/Image.