5S - it sounds so easy - but is very difficult to implement

When you hear about 5S the first time, you might think that it sounds easy to implement. But soon you will realize that 5S is difficult to implement - and even more difficult to maintain and improve!

5S stands for

1. Sort: Sort work place in ”in use” and ”not in use”.
2. Set in order: Put items in system.
3. Shine: Procedure for cleanliness.
4. Standardize: Procedure for how to leave the workplace.
5. Sustain: Ingraining into culture.

Possible results implementing 5S

• Improves ergonomics.
• Improves safety – no disorder.
• Improves quality – right tools for the right parts and processes.
• Gives pride to the work place.
• Easier to take over a work place from a colleague.
• Reduces changeover times.
• Gives a visible overview of work place – tools, parts, fixtures etc.
• Time spent on searching is reduced.
• Reduces demand for space.
• Improves productivity.

Challenges when implementing 5S

Some of the challenges are:

• The cultural change. It many companies it is widely "accepted" to borrow tools etc. from each other work tables - without returning them. It is also accepted to spend a lot of time searching for the same tools when they are needed. In these companies it is a huge cultural change to implement 5S.
• In many companies it is normal to have "personal tools". Meaning that tools are personal and that they employees are responsible for the tools. With 5S tools are no longer personal but belong to work stations.
• It is a great challenge to maintain a high 5S level. At good way is to appoint a 5S patrol consisting of employees from different departments. They should then audit each department e.g. monthly.

REMEMBER that 5S is a good test of the capability in the organization to implement Lean. If an organization is not able to maintain a high 5S level the same organization can not run Kanban, measure OEE etc.

By Mikkel Smith
Flexkom - download Lean tools online >
Flexkom Lean Academy - Scandinavian Lean Course Website >

When is a company Lean?

When can a company be considered Lean?

“Is my company Lean?” Many companies ask themselves whether their company is Lean or not. Actually it is my experience, that many of the companies that think they are about to be Lean - have a long way to go! Lean can give excellent results, but they do not show within the first year! Experience shows that it takes up to 3-4 years to “become Lean”. Remember - you never become Lean! Lean is not a static condition and you will never be able to say “now we are Lean”. Lean is a culture - a way to work and do things. Lean can therefore not be something you are - but a way you work!

“Lean is a company culture”

Even though Lean is a way to work, I will try to give 5 questions that can indicate whether you are on the right track!
The questions are for manufacturing companies:

• Does the top management have focus on Lean in words and actions? Do they talk about Lean on every meeting and do they constantly show in the production and recognize results?
• Is the production organized as a 5S workplace with a high level of order and systematism? And is the 5S level constantly improved?
• Is the “total process time” divided by the “total throughput time incl. all stocks” improved? The process times divided by the total throughput time should not be more than 0.1%. The stock turn should be more than 12.
• Is the planning horizon reduced? It should be reduced to at least day-to-day planning. A condition to reach this goal is reduced turn-over times and small batches - with a high OEE on bottlenecks.
• Are boards used for planning and problem solving?

Lean can give significant results

Using Lean production companies can achive the following results:

• Shorter lead time to customers
• Improved delivery service
• Increased capacity
• Improved product quality
• Reduced stocks
• Improved flexibility
• Higher productivity
• Improved safety level
• Improved ergonomics
• Visible management
• Improved job satisfaction
• Key performance indicators at all key points
• Continuous improvements
  

By Mikkel Smith
Flexkom – Download Lean tools online >
Website on Scandinavian Lean Courses >