Method: Productivity improvement methods
The 5S Foundation:-
An organization that wants to improve productivity at the shop-floor and establish a lean culture need to first set up their environment using the 5S tool. The goal of 5S is to create a work environment that is clean and well-organized. It consists of five elements:-
1. Sort - The first step is to determine the scope of the area. The key Lean tool used to “sort” is red tagging. It helps to reduce two main types of waste that are time (trying to look for something amidst the piles) and space (warehousing unused items). Start with a machine, warehouse rack or file storage location. Sorting is the key to 5S as it involves overcoming separation anxiety.
2. Straighten- Everything at its place and a place for everything! This step is focused on the use of visual management tools consisting of colours, storage areas and location to ensure every item has a home. Limitations on horizontal surfaces are recommended. This is the design stage to determine what the new area will look like, consider the required tools from the Sort stage and to question when a tool may be needed.
3. Shine - Facility and equipment maintenance is a nonstop challenge in the food manufacturing industry. However, the Shine step is the key to identification of potential problem areas. The intent of the Shine step is to help identify issues. Equipment that is maintained and cleaned is far easier to determine if something is wrong than equipment that is not maintained. The same is true for quality inspection areas and other administrative functions. In this, one should define
- What exactly needs to be kept clean?
- How will it be cleaned?
- Who will do the cleaning?
- What level of cleanliness is acceptable?
New tools or equipment that does not have a home or storage location will stand out and must be addressed.
4. Standardize - In developing a standard, only one question needs to be asked when a problem arises. “Was the standard followed?” If the answer is yes and the problem occurred, then the standard comes into question. If the answer is no, then an investigation into deviation from standard is needed.It is important to note that the best standard is always one that is clear, simple and visual. Some examples of standardizing would include a checklist, production board and a tool shadow board.
5. Sustain - The most difficult stage of the 5S tool is to maintain the improvements and monitor the system. The changes from the 5S become a standard. Sustaining change requires discipline and communication. Only a healthy culture can maintain and sustain the 5S changes.
5S is a five-step process that transforms a traditional work site into a visual factory and lays the foundation for a productive entity. In order for an organization to stay productive, it is very important that they “sustain” what they have already implemented with the first four steps mentioned above. Ways to accomplish this may include the development and usage of metrics, which will show any deficiencies in the process, and training, which will ensure that each individual is conducting the standard effectively.
5S can benefit any organization and brings unique benefits to the food and beverage industry. 5S benefits your customers by enabling you to bring the highest quality at the lowest cost and the best lead time to the marketplace. One benefit that is unique to food and beverage is that 5S also enables you to minimize food safety risks for your consumers.5S benefits your company by improving your profitability, credibility, flexibility, and integrity while increasing employee engagement and ownership. 5S benefits your employees by improving their safety and job security. It also encourages employee involvement and increases job satisfaction.