5S in The Workplace (Manufacturing Facilities)

Many manufacturing facilities have opted to follow the path towards a “5S” workplace
organizational and housekeeping methodology as part of continuous improvement or lean
manufacturing processes. The term refers to five steps – sort, set in order, shine, standardize,
and sustain – that are also sometimes known as the 5 pillars of a visual workplace.

The 5S system is a good starting point for all improvement efforts aiming to drive out waste from the
manufacturing process, and ultimately improve a company’s bottom line by improving products and
services, and lowering costs. Many companies are seeking to making operations more efficient, and the
concept is especially attractive to older manufacturing facilities looking to improve the bottom line by
reducing their costs.

“A place for everything, and everything in its place” is the mantra of the 5S method, and storage and
workspace systems allow improved organization and maximum use of cubic space for the highest
density storage. The result is an improved manufacturing process and the lowest overall cost for goods
produced.

Pillar What does it mean? Why is it important? What problems are

avoided?
Sort  Remove all  Space, time,  The factory
items not money, energy, becomes
needed for and other increasingly
current resources can be crowded and
production managed and used hard to work in.
operations. most effectively.  Storage of
 Leave only the  Reduces problems unneeded items
bare essentials: and annoyances in gets in the way
When in doubt, the work flow. of
throw it out.  Improves communication.
communication  Time wasted
between workers. searching for
 Increases product parts/tools.
quality.  Unneeded
 Enhances inventory and
productivity. machinery are
costly to
maintain.
 Excess stock
hides
production
problems.
 Unneeded
items and
equipment
make it harder
 to improve the
process flow

Set in order  Arrange  Eliminates many  Motion waste.

needed items kinds of waste,  Searching
so that they are including: waste.
easy to use.  Searching waste.  Waste of
 Label items so  Waste due to human energy.
that anyone difficulty in using  Waste of excess
can find them items. inventory.
or put them  Waste due to  Waste of
away. difficulty in defective
returning items. products.
 Waste of unsafe
conditions.
Shine  Keep  Turn the workplace  Lack of sunlight
everything, into a clean, bright can lead to
every day, place where poor morale
swept and everyone will enjoy and inefficient
clean. working. work.
  Keep things in a  Defects are less
condition so it is obvious.
ready to be used  Puddles of oil
when needed. and water
cause slipping
and injuries.
 Machines that
do not receive
sufficient
maintenance
tend to break
down and cause
defects.
Standardize  Integrates Sort,  By ensuring  Conditions go
Set in Order, conditions do not back to their
and Shine into deteriorate to old undesirable
a unified former state, levels.
whole. facilitates  Work areas are
implementation of dirty and
the first three cluttered.
pillars.  Tool storage
sites become
disorganized
and time
wasted
searching for
 tools.
 Clutter starts to
accumulate
over time.
 Backsliding
occurs.
Sustain  Making a habit  Consequences of  Unneeded
of properly not keeping to the items begin
maintaining course of action piling up.
correct greater than  Tools and jigs
procedures. consequences of do not get
 Instill discipline keeping to it. returned to
necessary to their
avoid designated
backsliding. places.
  No matter how
dirty equipment
becomes,
nothing is done
to clean it.
 Items are left in
a hazardous
orientation.
 Dark, dirty,
disorganized
workplace
results in lower
morale.

Source: Lista International

Hi QC,

In line with our ongoing 5S program, I showed you a brief definition of what the step means in a
manufacturing context, why it’s important, and the list of problems it avoids if implemented.
We had our dry run of doing our 5S checklist last week and now we are officially applying our 5S
checklist as part of our everyday routine. Included in your area’s responsibility are its
countertop,maintenance of equipments, cleanliness and availability of glasswares, trash bin,
drawers, shelves and its floor perimeter. I will monitor our 5S checklist every day that will serve
as an internal audit. I will also recognize and report to Maam Jacq and Maam Cyndi the analyst
that will be the most outstanding in applying 5S in his/her every day work. As a reminder, I
expect each and one of us to sustain the cleanliness of your assigned area every time. I know at
first it will be hard given that we are expecting voluminous samples to even keep track of our
area’s cleanliness, but before you know it, it will develop as a habit and it will be undemanding
to each one of us. For any questions and clarification, feel free to ask me. 

I am hoping for everyone’s cooperation in this program. Thank you!

-Kristine 