By Noman Husain, LEAN Coach

One of the most effective and widely used Lean tools is 5S. 5S is a workplace organization and visual controls methodology that refer to five Japanese words—seiri, seiton, seiso, seiketsu, and shitsuke.

Although Toyota is credited with the development and popularization of 5S methodology, however, the origin of 5S is rooted in the works of American pioneers who were studied by Japanese managers including Sakichi Toyoda, Kiichiro Toyoda and Taaichi Ohno. Among the notable Americans were Frederick W. Taylor's Scientific Management (1911) and Henry Ford (1922). Indeed, Ford's CANDO program (Cleaning up, Arranging, Neatness, Discipline, Ongoing Improvement), which builds on Taylor's work, appears as the obvious origin for 5S.

Phases of 5S:

1. Sort (Seiri)

2. Store (Seiton)

3. Shine (Seiso)

4. Standardize (Seiketsu)

5. Sustain (Shitsuke)

1. Sort

Sorting is separating the essential materials from the nonessential. Nonessential items are those not needed for present production. The procedure that involves identifying the nonessential items in a work area is called “tagging.” The goal of sorting is to simplify the work environment and break the ‘just in case’ mentality. When in doubt, move it out!

2. Store

Storing involves organizing the essential materials in the workplace. This phase can also be referred to as Simplifying. Make it visual and obvious if something is out of place. Make it easy for everyone to find and use them – use “30 second” rule. The goal of storing is to eliminate wasted time looking for materials and tools. A place for everything and everything in its place.

3. Shine

Shine is cleaning the work area and keeping it clean on a regular basis. It is regimented, scheduled cleaning of the entire work area. The purpose of shine is to rid the workplace of all dust and dirt (dirt is often the root cause of premature equipment wear and product failure). A cleaner workplace allows for quicker problem detection and is a safer workplace. A key point is that maintaining cleanliness should be part of the daily work - not an occasional activity initiated when things get too messy.

4. Standardize

Standardize means to set up the rules for Sort, Store and Shine, implement the rules on a consistent basis and maintain the workplace at a level in which non conformities become obvious. Standards must be simple and easy to follow. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's.

5. Sustain

To sustain is to perform the Five S’s on an ongoing and systematic basis until it become a way of life. Sustaining is the continuation of sort, straighten, shine and standard. Measurement drives behavior, and if we do not pay attention to the sustainment it will degrade. This is the most difficult step. If nothing is done, nothing will improve

Implementing and maintaining 5S will pay huge dividends to the company by creating safer workplace, increasing productivity, reducing waste and improving morale.