Cleanliness in the workspace is important. This includes equipment, tools, floors, walls, and other surfaces. If an employee personally monitors the cleanliness of his or her workspace, he or she may notice problems that can be quickly corrected and prevented.
For example, in a large plant, in one of the workshops, a section of the floor was oily and covered in dirt. The machine in this section failed. After inspection, the repair team determined that due to the dirt and oil spilled on the floor, they did not notice in time that the machine mounting bolts had loosened and due to vibration, the machine body cracked, which led to a major breakdown. If the floor in this section had been clean, the expensive equipment would not have been disabled.
Standardize order
Maintaining order in everything is the key to success. Repeating the first three steps of the 5S system should become a habit. For this purpose, standards for maintaining order are drawn up, which all employees follow.
Structure of the 5S system - Standardization
Source: shutterstock.com
It is necessary to describe all daily actions of the staff, create instructions and checklists to ensure compliance with the standard.
The workers themselves should monitor the maintenance of checklists, and the managers should monitor this. The staff can evaluate compliance with the 5S system rules themselves. The employee's evaluation should be close to his workplace so that he knows how and which indicators to improve.
Sustain
Training and testing of knowledge on the 5S system should cover all employees, from workers to company directors. Only in this way will compliance with 5S requirements become the norm and part of the corporate culture.
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Alexander Kuleshov
Alexander Kuleshov
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Implementation of the 5S system
The implementation of 5S principles in a company goes through several stages, the structure and names of which are determined by the company itself. However, the standard PDCA cycle (Plan/Prepare – Do – Check – Act) can serve as a good generalization of possible options.
The result of standardization should be a package of documents regulating the previous phases of 5S, as well as a system of visual control and informing employees.
The first phase is preparation
At this stage the following tasks are performed:
A decision is made to apply the 5S system.
A project leader is appointed.
The project team is being formed.
Change zones are identified.
A training plan is being developed and implemented.
The current condition is assessed using photo reports.
Target indicators are set.
Staff are informed of upcoming chang