5S + Safety = Lean 6S Safety

What is 5S?
5S is a system for organizing spaces so work can be performed efficiently, effectively, and safely. This system focuses on putting everything where it belongs and keeping the workplace clean, which makes it easier for people to do their jobs without wasting time or risking injury.

5S Translation
The term 5S comes from five Japanese words:

1. Seiri
2. Seiton
3. Seiso
4. Seiketsu
5. Shitsuke

In English, these words are often translated to:
1. Sort
2. Set in Order
3. Shine
4. Standardize
5. Sustain
6. Safety (Additional)

Each S represents one part of a five-step process that can improve the overall function of a business.

The Origins of 5S – 5S & Lean Manufacturing

5S began as part of the Toyota Production System (TPS), the manufacturing method begun by leaders at the Toyota Motor Company in the early and mid-20th century. This system, often referred to as Lean manufacturing in the West, aims to increase the value of products or services for customers. This is often accomplished by finding and eliminating waste from production processes.

Lean manufacturing involves the use of many tools such as 5S, kaizen, kanban, jidoka, heijunka, and poka-yoke. 5S is considered a foundational part of the Toyota Production System because until the workplace is in a clean, organized state, achieving consistently good results is difficult. A messy, cluttered space can lead to mistakes, slowdowns in production, and even accidents, all of which interrupt operations and negatively impact a company.

By having a systematically organized facility, a company increases the likelihood that production will occur exactly as it should.

What Are the 5 S's?
The 5S concept might sound a little abstract at this point, but in reality it's a very practical, hands-on tool that everyone in the workplace can be a part of.

5S involves assessing everything present in a space, removing what's unnecessary, organizing things logically, performing housekeeping tasks, and keeping this cycle going. Organize, clean, repeat.

Let's take a closer look at each of the parts of 6S.

1. 5S Seiri, or in English; Sort, Clearing, Classify.  In this stage we remove all clutter and unwanted items leaving only the tools, equipment, components, and machines that are required on a daily basis.

2. 5S Seiton, or in English; Straighten, Simplify, Set in order, Configure. This stage is where we organize all of the remaining items; using ergonomic principles to locate items where they minimize movement and reduce stress. We also ensure that items are clearly identified and have a clearly identified home – “A place for everything, and everything in its place.

3. 5S Seiso, or in English; Sweep, shine, Scrub, Clean and Check. This is the cleaning and painting of the area to bring it to a “new” standard. The reason for this is not just to make the area look pretty but to ensure that things like leaks and other issues stand out against the otherwise clean area

4.5S Seiketsu, or in English; Standardize, stabilize, Conformity. During this phase of 6S we standardize the previous stages of the implementation by ensuring common color codes and ways of working.

5. 5S Shitsuke, or in English; Sustain, self discipline, custom and practice. This is where we try to make the process part of the culture of the company to ensure the ongoing implementation and improvement of this initiative.

6. The 6th “S”; Safety, we now concentrate on safety aspects of our initiative, reviewing every action and each area to ensure that we have not overlooked any potential hazards.

Objectives
 To establish effective house-keeping procedures in the silk
reeling working floor.
 To implement and maintain an effective system to achieve a
conducive environment for quality.
 Identify, reduce and eliminate waste
 Enhance team work
 Enhance operation effectiveness in a better working
environment
 From the basic advance model for productivity and quality
improvement

Methodology adopted
 Discussion with mangers to identify the department for 6s
implementation
 Using the 6s master scoring criteria, record the present level of
performance
 Evaluate the performance of the stores after 6s implementation

Benefits of 6S
 Reduced costs.
 Higher quality
 Greater employee satisfaction
 Increased productivity
 A safer work environment
 Workroom develops into clean and neat.
 Better place utilization
 Flaws condensed by error proofing.
 Clear and validated procedures recognized.
 Better consumer acceptability

AnY QuerY :

Saikat Hossain Shohel

E-Mail: saikatsh7@gmail.com