Modern management in the company is not only the quality management system based on the ISO series 9000:2000 standards, but pursuit to the continuous improvement, so this is the philosophy of the Total Quality Management .
In the frames of implementation of the Total Quality Management on the operating level more and more popular becomes the idea of so called 5S.
The 5S method begins each program of improvement. It is the tool for helping the analysis of processes running on the workplace. The 5S is the methodology of creation and maintaining well organized, clean, high effective and high quality workplace. Its result is the effective organization of the
workplace, reduction of work’s environment, elimination of losses connected with failures and breaks, improvement of the quality and safety of work.
The philosophy of the 5S has its roots in Japan. Name 5S is the acronym of five Japanese words of the following meanings:
Ø Seiri (sort),
Ø Seiton (set in order),
Ø Seiso (shine),
Ø Seiketsu (standardize),
Ø Shitsuke (sustain).
Seiri (sorting, organization of the workplace, elimination of unnecessary materials). Refers to the practice of sorting through all the tools, materials, etc., in the work area and keeping only essential items. Everything else is stored or discarded. This leads to fewer hazards and less clutter to interfere with productive work.
Seiton (set in order, place for everything). Focuses on the need for the workplace in order. Tools, equipment, and materials must be systematically arranged for the easiest and the most efficient access. There must be a place for everything, and everything must be in its place.
Seiso (shine, cleaning, removing of wastes, dust etc.). Indicates the need to keep the workplace clean as well as neat. Cleaning in Japanese companies is a daily activity. At the end of each shift, the work area is cleaned up and everything is restored to its place.
Seiketsu (standardize, constant place for things, constant rules of organization, storage and keeping cleanness). Allows for control and consistency. Basic housekeeping standards apply everywhere in the facility. Everyone knows exactly what his or her responsibilities are. Housekeeping duties are part of regular work routines.
Shitsuke (sustain, automatic realization of above-mentioned rules). Refers to maintaining standards and keeping the facility in safe and efficient order day after day, year after year. Implementing the 5S rules should begin from trainings of productive workers in the range of the 5S’s elements and advantages from their usage. It is important that all participants of trainings will understand the need of using the 5S rules on the own workplace and will agree on the changes. During trainings it is essential to train the usage of all rules on the clear example, so that every participant can understand the methodology of realization of the 5S’s elements. Very important fact is that these rules do not refer only to the productive positions, but also refer to the warehouse, office positions and others.
Main goals of 5S
The main purpose of a program based on 5S Method is the maintenance of the workplace order, in order to it stays always organized, arranged and cleaned, under standard conditions and with the necessary discipline for getting the best performance in the activities of each person, due to be also performed in the particular life of each person.
The main benefits of the 5S program are:
1. More productivity for decreasing of waste of time seeking by objects. It is only in the environment the objects necessaries to the work.
2. Decreasing of expenses and better exploitation of materials. The excessive accumulation of materials tends to the degeneration and creates waste.
3. Improvement of the quality of products and services.
4. More discipline
5. Less risks of occupational accidents.
6. More satisfaction of people with the job.
5S has little to do with creating a clean and tidy work area where everything is neat, near-by, and easy and fast to get to. That is indeed what you see when you have a great 5S workplace, but that is not what 5S is for.
5S is to there to help you do masterly work. Its purpose is to help people do perfect work every time.
5S is really about:
- Preventing mistakes that ruin a job and makes scrap and rework
- Making sure equipment is reliable and works properly to make a perfect item every time
- Removing and preventing useless variation in work activities and machine performance
- Delivering exact quality products and service ever more quickly
- Keeping people and plant safe from hazards and harm
Actually, that is what every business wants. To achieve those vital performance benefits it just happens that you need to Sort, Straighten, Shine, Standardise and Sustain in order to create the right workplace situation that will deliver the competitive performance a business needs.
So do not tell your people that 5S is only about workplace management and cleanliness; rather teach them that through their personal workplace practices they set themselves up to do great work. By doing great work they will build a competitive company and thereby secure their future.
They will help build a world-class operation whose products or service will attract new customers and keep them in jobs. If they use 5S well they will be creating work security for themselves and building a safer, happier work environment where people make a top-quality product every time. 5S is not about being clean, tidy and neat; it is about always doing excellent quality work your customers love. To do that well you need to be clean, tidy and neat!
In order to get that awareness into your people run a small pilot project where 5S is used in the workplace. Let them see that 5S works to turn disorganized, messy work into a highly efficient and effective operation.
Get your people to experience and see the effects of the pilot 5S improvement project in several ways, e.g. show it on graphs and charts on a communication board; get the guys in the 5S pilot trial to do tool box talks to the others about what they have learned, and the problems that they solved; let people go and see what the people in the pilot trial are doing, etc.
It is important for your people to know that working in 5S teams will be positive, where open discussion develops amongst its members and people get friendly and supportive assistance from each other. The pilot team applies 5S by doing it. They and everyone in the operation immediately gets feedback on how well that worked through the measurements, and by seeing the effectiveness of the 5S improvement efforts for themselves. Once your people see that 5S workplace management works, they will want to do 5S too.
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