Lean

Implementing 5S in Your Company

By John Knotts Updated on August 15th, 2023

In an era where business competition is fierce, having a streamlined operation can give you a significant edge. One effective strategy to achieve operational efficiency is the 5S methodology. But how do you know if your company needs 5S? And if it does, how do you go about implementing it? Let us explore…

One of the first steps in any process improvement journey is recognizing the need for change. Before diving headfirst into implementing 5S, it is crucial to assess whether your company genuinely needs it.

Look for some of these telltale signs during gemba walks and stand-in-the-circle activities:

Cluttered Workspaces: Overflowing desks, benches, and random items without a designated place.
Frequent Searching: If employees are always on a treasure hunt for tools or documents, there’s room for improvement.
Safety Concerns: Tripping hazards, blocked emergency exits, or unsanitary conditions.
Low Morale: Disorganized workspaces can lead to frustrated employees.
Waste Accumulation: Excessive inventory or materials that are never used.
Inconsistent Work Processes: Varied methods for the same tasks lead to inconsistent outcomes.
Customer Complaints: Feedback on delays, errors, or the appearance of the workspace.

If any of the above resonates with your company’s situation, it is time to consider 5S.

The 5S methodology is systematic and straightforward.

Start with awareness and training, ensuring everyone understands the importance and mechanics of 5S. My recommendation is not to train the entire business. Evaluate the current state of your business, documenting areas that need improvement. Pick one area that is most receptive to change — these can be your change champions.

The actual 5S process then begins with ‘Sort,’ where you remove unnecessary items. Next, ‘Set in order’ focuses on organizing items for an efficient workflow. ‘Shine’ emphasizes cleaning the workspace, ensuring it is free from dust, dirt, and waste. With the foundation set, ‘Standardize’ creates procedures to maintain the newfound order. Finally, ‘Sustain’ embeds the 5S principles into the company culture, ensuring long-term adherence.

While the 5S system offers tremendous benefits, integrating it with other operational efficiency tools can amplify its impact. For instance, the Kaizen approach emphasizes continuous, incremental improvements, which can dovetail nicely with 5S efforts. Tools like Value Stream Mapping can help visualize the flow of materials and information, making organization easier. Kanban, a visual tool, can be integrated into the “Set in order” phase of 5S, ensuring resources are available as and when needed. Lastly, using the PDCA (Plan-Do-Check-Act) loop can further refine and evolve your 5S initiatives.

The 5S methodology is more than just a tidying-up exercise. It is about fostering a culture of efficiency, safety, and productivity. By recognizing when to implement 5S and complementing it with other operational excellence tools, businesses can position themselves for success in today’s competitive market.

John Knotts

As a Lean Six Sigma Master Black Belt, John has over 30 years of experience in operational excellence. He served 21 years in the US Air Force -- 11 as an internal coach and consultant. He led strategy and change efforts with Booz | Allen | Hamilton for 18 clients. He was an internal coach and consultant for Fortune 100, United Services Automobile Association. And, he’s been a solopreneur growing, scaling, and improving companies for over 12 years. In addition to multiple certifications in change management, project management, agile, and information technology, John has a Bachelor’s in Management, a Master’s in Quality Systems Management, and a Ph.D. in Industrial and Organizational Psychology.

ALhussain Abushady
September 27, 2023 - 1:45 am
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