What is 5S?

5S ... or 6S when special attention is added for safety, is a method used to help us make our workplace safe, clean, neat and organized.  It provides a specific location for everything, and eliminates anything not required. It embeds quality into the workforce.

5S is most commonly used where products are being made or service is being performed but anyone that follows any process can benefit from 5S.  

See the five elements of 5S below that contribute to the acronym of 5S. 

Mature 5S programs:

• Empower workers to manage their own area and measure their own quality and efficiency.
• Enable process improvement to be pushed down to those doing the work.
• Span across all departments from office workers to production line workers.
• Continuously evolve and improve forever.

• Shadow boards are one way that areas can apply the straighten element of 5S.  See Straighten below.
• This example highlights how two tools are not in their place.  A 5S audit would record this as a problem if those tools were not being used in the area at that time. 
• Shadow boards enable a quick inventory of the tools needed for that task to be performed. 

• Sort what is not needed, sort through, then toss out; "When in doubt, throw it out!"
  • A good way to attack the first S is by having a “red tag event”.  Inevitably, items fall into a few categories:
    • items we use routinely,
    • items we use infrequently,
    • items we no longer use,
    • items we might use.
  • The team of people from the work area put a red tag on each item that is not used in the regular performance of work.  The tag usually has identification data showing what the item is called, in what department it is stored, as well as anything other useful information.  It also shows a date. The red tagged items can then be stored either be tossed out immediately (recycled, scrapped, sold, donated, etc.) or kept for some number of days (30, 90, 180).  This allows a group to “re-discover” the use for an item with uncertain usage.  It is a good idea to write the expiration date and method of disposal on the tag.  Review the red tagged items periodically and after the number of days expire (per the date on the tag), dispose of them as stated on the tag.
• Straighten what must be kept; make it visible and self-explanatory so everyone knows what goes where.
  • Labeling, color-coding, and special storage that provides “fitted” spaces for items are a popular way to do this.  Also popular are “shadow boards” that allow users to hang item on a board painted with silhouettes of the items belonging there.  Label the item AND the place where it goes.
• Shine everything that remains; clean equipment, tools, and workplace.
  • It is common to use the “shine” activity as an opportunity for operators to closely inspect the piece of equipment they are working on to look for wear or potential maintenance issues.  Calling for repairs or maintenance before downtime is incurred is a great way to reduce costs.
• Spread the clean routine to other areas;  make it more automatic.
  • Standardize the items used in similar jobs (same staplers, scissors, tape dispensers, tape measures, etc).  Standardize the methods of display.  This reduces cost by simplifying training.  Lean uses simple systems and replicates them “cookie-cutter” style whenever possible.  Spread the methodology throughout the company.
• Standardize with discipline to stick to the rules and make them a habit.
  • Sustain the savings and improvements by institutionalizing the program.  It is work to start a 5S program and it is important not to regress to old habits. Make checklists and check them DAILY.   Make people and groups accountable.  Incentivize the people and make the program fun.   Make sure everyone knows how the program is scored and understands their role.  Help the team develop the discipline to stick to the rules and make them a habit.
• Note that a sixth S is often used to represent special emphasis on Safety.