7/10/2019 5S | 5S Methodology | Quality-One

Introduction to 5S
With the ever changing economic climate, many organizations
are periodically adjusting their resources to align with business
strategy. This often results in the need to achieve more work
with fewer resources. In order to remain successful, businesses
must become more efficient, reduce waste and thereby reduce
cost. We must find ways to do what we are currently doing in
less time and at a lower cost. One way we can accomplish this
is through the use of 5S Principles. The 5S Principles are very
effective at identifying and eliminating waste and increasing
efficiency. There is a lot of information about 5S and how it
came to be. The popular belief is that the Japanese invented the
5S Methodology because the letter “S” stands for five Japanese
words, that when translated to roman script, start with the letter
“S”. In actuality, the principles within 5S were being utilized
decades before by Mr. Henry Ford. It has been reported that
prior to 1920, Mr. Ford was using CANDO in his manufacturing
processes. The acronym CANDO stands for Cleaning up,
Arranging, Neatness, Discipline and Ongoing improvement. In
the 1950s, representatives from Toyota visited the Ford facilities
to be trained in automotive mass production methods. The
Japanese later adapted the CANDO methods and applied them
in their production facilities. Some commonly used words
describing the steps in 5S are Sort, Set, Shine, Standardize and
Sustain. Throughout different companies, various words are
used that have similar meanings. No matter what specific words
are used to identify the steps in 5S, the purpose remains the
same: create a clean, organized and efficient work environment.

What is 5S
The 5S Method is a standardized process that when properly
implemented creates and maintains an organized, safe, clean
and efficient workplace. Improved visual controls are
implemented as part of 5S to make any process non-
conformance’s obvious and easily detectable. 5S is often one
element of a larger Lean initiative and promotes continuous
improvement. The 5S list is as follows:
Seiri / Sort: Separating of the essential from the
nonessential items

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Seiton / Straighten: Organizing the essential materials

where everything has its place
Seiso / Shine: Cleaning the work area
Seiketsu / Standardize: Establishing a system to maintain
and make 5S a habit
Shitsuke / Sustain: Establishing a safe and sanitary work
environment (Safety)

The 5S Principles are recognized in many industries as effective

tools for improving workplace organization, reducing waste and
increasing efficiency. Organizations should be careful to not
allow the 5S Principles to become viewed as the whole of the
company’s improvement efforts. Otherwise it could become the
end goal of your company’s improvement process instead of a
key part of a larger continuous improvement journey. The
greatest benefit from using 5S is realized when it is part of a
larger initiative and the entire organization has adopted its
principles. 5S is more than a system; it is a business philosophy
and should be integrated into the organization’s culture.

5S Diagram

Why Implement 5S
There are many benefits to implementing the 5S Methods into a
work area on the production line or in the business office. To not
only survive but thrive in business today, cost must be controlled
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and waste must be avoided or eliminated. The 5S steps, when

implemented properly, can identify and reduce many forms of
waste in any process or workstation. An organized work area
reduces excessive motion and wasted time looking for the right
tool. The visual aspect of the 5S Methodology is also very
effective. When everything has a place, it is easier to spot
something missing or misplaced. A clean work area helps draw
attention to possible problems or safety hazards. A clean floor
helps spot any leaks or spills could indicate machine
maintenance and prevent slips and falls. Furthermore,
encouraging people to watch for and address problems can
result in a positive change to an organizations culture.
Therefore, the 5S Principles implemented as part of a larger
Lean initiative or as a standalone tool can reduce waste,
improve quality, promote safety and drive continuous
improvement.

How to Implement 5S
Sort
The first step in 5S is sorting. During sorting the team should go
through all items in the work area including any tools, supplies,
bulk storage parts, etc. The 5S team leader should review and
evaluate every item with the group. This will help to identify
which items are essential for getting the job done effectively and
efficiently. If the item is essential for everyday operations it
should be tagged and cataloged. If the item is not essential,
determine how often it is used in the performance of work in that
area. If it is a bulk item, decide the proper amount to be kept in
the area and move the remaining quantity to storage. Excess
inventory is one form of waste and should be eliminated during
the 5S activities.

Straighten
Designate a place for all items that remain in the work area. Put
all items in their designated location. An often referenced quote
is “A place for everything and everything in its place”. During the
straighten step, look for ways to reduce or eliminate waste. One
form of waste in a process is unnecessary operator motion or
movement. Therefore, frequently used tools and supplies should
be stored in the immediate work area close to the operator. One
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effective method commonly used to avoid wasted time

searching for the correct tool is constructing shadow boards for
all essential tools. Items that are not used as often should be
stored based on their frequency of use. All parts bins should be
properly labeled. The label should include part number, part
description, storage location and the recommended min / max
quantities. A properly straightened work area allows the
operator to quickly review and verify that they have everything
they need to successfully perform their task at hand.

Shine
The next step is to clean everything in the area and remove any
trash. To be effective we must keep the area and any related
equipment clean. Dirty process equipment can actually
increase the potential for process variability and lead to
equipment failure. Lost time due to equipment failure is
considered waste and non-value-added time. A dirty area can
also contribute to safety issues that have the potential to cause
a worker to be injured. Operators should clean their areas at the
end of each shift. By doing this they will likely notice anything
out of the ordinary such as oil or lubricant leaks, worn lift cables,
burnt out bulbs, dirty sensors, etc. The purpose is to reduce
waste and improve operator safety and efficiency.

Standardize
The fourth step has been called the most important step in the
5S Process. In this step we must develop the standards for the
5S system. They will be the standards by which the previous 5S
steps are measured and maintained. In this step, work
instructions, checklists, standard work and other documentation
are developed. Without work instructions or standard work,
operators tend to gradually just do things their own way instead
of what was determined by the team. The use of visual
management is very valuable in this phase. Color coding and
standard colors for the surroundings are sometimes used.
Photos of the area in the standard 5S configuration are often
posted for easier identification of non-conformance’s. The
operators are trained to detect non-conforming conditions and
correct them immediately. Schedules should also be developed
for regular maintenance activities in each area.

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Sustain
This step in the 5S Process can sometimes become the most
challenging of all the five steps. Sustaining is the continuation of
the Sort, Straighten, Shine and Standardize steps. It is the most
important step in that it addresses the need to perform 5S on a
consistent and systematic basis. During this step a standard
audit system is usually developed and implemented. The goal of
the sustain step is to ingrain the 5S process into the company
culture. The company must strive to make 5S a way of life so
the benefits gained through the exercise can be maintained. 5S
is not a one-time exercise. Following the 5S Process must
become a habit.

5S + 1
Some organizations have added an additional step and titled
their process 5S + 1. The additional step being applied is safety.
The goal of adding this step is to foster a culture that enhances
safety by identifying any workplace hazards and removing them.
In addition, tools and workstations are selected or designed with
proper ergonomics in mind. The emphasis being that in each of
the other 5S steps the motto is “Safety First”.
Many companies have implemented 5S into all areas of their
business. The greatest benefits are usually realized when 5S is
implemented as part of a larger Lean initiative within the
organization. If implemented properly, 5S can help drive your
company’s lean initiatives and be a powerful stimulus for
developing a continuous improvement culture.

The 8 Forms of Waste:

As previously stated, 5S Principles are effective tools for
reducing waste, improving quality, increasing efficiency,
promoting safety and encouraging continuous improvement.
When applying 5S Methods you should always remember the
various forms which waste can take:
Overproduction – Producing more product than required or
producing parts faster than the downstream processes can
utilize it. Strive to produce the proper amount at the proper
time.
Excessive Inventory – This can be a direct result of
overproduction or it could be due to poor purchasing
practices. Over purchasing supplies because we got a great

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deal sometimes is no deal at all. Excessive or unneeded

inventory can propagate other forms of waste.
Inappropriate or Non Value Added Processing – Waste is
incurred through use of the wrong tool, performing needless
operations or not using the most efficient processes or tools
for the job. Beware of the phrase “Because we have always
done it this way”. The right process and the correct tools can
reduce waste in your process.
Waiting – Time and resources are wasted when waiting on
parts, supplies or information.
Transportation – Excessive travel or movement of materials
is waste. Proper planning and process layout can help
reduce or eliminate excess transportation. The use of value
stream mapping can help the team visualize exactly how
much the material is traveling.
Unnecessary Motion – Any movement or motion performed
by the operator that does not add value is waste. During
your 5S exercise examine the motions required to perform
the task. Organize the workstation so all tools and supplies
are easily located and within easy reach. In some cases, re-
sequencing certain process steps can reduce excessive and
redundant movement or motion by the operator. By reducing
or eliminating the waste of excess motion you are also
creating a more ergonomic workstation. Always consider
safety first.
Defects – This form of waste is one of the worst of all.
Producing non-conforming parts or assemblies increases
scrap, reduces process efficiency, wastes machine, process
or assembly time and causes non-value added tool wear.
Defects can also create additional waste in the form of wait
time when the downstream operations run out of usable
parts.
Untapped Employee Creativity (potential) – Many
companies are now realizing that their best asset is their
employees. Companies must create an atmosphere where
ideas are encouraged. Some of the most successful
organizations have created a culture where employee’s
ideas are really heard and evaluated. When their good ideas
are implemented, the employee is recognized and
rewarded. You never know where the next great idea is
going to come from.

When you are implementing your 5S program or other lean tools

watch out for the various forms of waste. Take action to
eliminate waste in your processes. Get the team members
involved and encourage them to provide ideas for
improvements. When teams work together to recognize,
address and eliminate waste and improve their workplace, they
will take ownership of the process. They are more likely to spot
any non-conformance’s in the future. The 5S Principles will

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