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Abstract
Purpose – The purpose of this paper is to use the 5S tool to assist a small-scale manufacturing
organization to become more productive and more efficient.
Design/methodology/approach – A simple approach has been adopted to create the teams for
implementing 5S. Cause-and-effect diagram has been studied for shop floor analysis. Later, four data
collection methods have been used to ensure right implementation of the 5S.
Findings – In the frames of this case study, it has been analyzed that implementation of “5S” resulted
in overall improvement of the organization. With the implementation of “5S”, major benefits in the form
of tool searching time have been achieved. Tool searching time from shop floor has been reduced from
30 minutes to 5 minutes. “5S” audit has been conducted in the organization. “5S” audit score has been
increased from 7 (Week 1) to 55 (Week 20).
Practical implications – 5S is a powerful tool and can be implemented in various industries whether
micro, small, medium or large. Implementation of 5S has large horizontal development and can be
implemented in all the workstations of an organization.
Originality/value – The publications and case study presented in this paper will be useful to
researchers, professionals and others concerned with this subject to understand the significance of 5S.
Keywords Continuous improvement, Lean manufacturing, Organizational effectiveness, 5S
Paper type Case study
1. Introduction to 5S
The 5S is the English meaning of five Japanese words which stands for Seiri (sorting),
Seiton (set in order), Seiso (sweep), Seiketsu (standardize) and Shitsuke (sustain)
(Ho et al., 1995; Ho, 1997; Vasudevan, 1998). In mid 1950s, Japan was the first country to
use the 5S approach to assist a manufacturing sector organization (Korkut et al., 2009).
Implementing 5S in the organization is one of the important steps toward continuous
International Journal of Lean Six
improvement. Implementing 5S ensures continuous improvement in housekeeping and Sigma
results in better safety standards and environment (Ho, 1999; Mente, 1994). To start with Vol. 6 No. 1, 2015
pp. 73-88
5S implementation, there is a need of developing a common language that is understood © Emerald Group Publishing Limited
2040-4166
by all, so that people in the organization can communicate with each other (Sethi and Pal, DOI 10.1108/IJLSS-08-2013-0047
IJLSS 1995). However, 5S is a practice which cannot be implemented without self-discipline
6,1 (Pheng, 2001). There are many problems which simply can be solved by organizing the
5S team (Ho, 1999a, 1999b). Organizing the 5S team results in establishing a quality
environment in the firm (Hough, 1998; Mente, 1994; Sethi and Pal, 1995). A quality
environment includes both cleanliness and order (Pheng and Khoo, 2001; Saraph et al.,
1989). 5S becomes a more effective approach when it is integrated with a management
74 system (Sevim, 2005). Support from the management level is a must to gain potential
benefits from 5S implementation (Narasimhan, 2009). Schools, homes, workplaces and
communities all of them can be improved by 5S activities (Gapp et al., 2008). 5S
implementation brings the plant to a neat and organized state and results in
improvement in overall productivity of the product (Gunasekran and Lyu, 1997).
Employee learning and participation is the first benefit observed when 5S is
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2. Literature review
2.1 Seiri (sorting)
Sorting is the first step of 5S and its main idea is to eliminate the unnecessary items from
the workplace. Red tagging is done to the items which are not required in the
organization. The items which are rarely used are moved to a more organized storage
area outside of the work area. Items which are completely not necessary are disposed
from the organization (Peterson and Smith, 2001). Sorting helps in eliminating broken
tools, scrap and obsolete jigs and fixtures (Harrington, 2000). This makes item flow
smoother and workers work and move easily. Specify the work areas to be evaluated
and identify type of items which need to be evaluated. In setting red-tag criteria, one
should ask the questions: How much is it needed? How often is it needed? Is it useful?
After all these questions are answered, attach the red tag and decide what actions are to
be taken (Dudek-Burlikowska, 2006). Documentation of the results is the next process so
as to measure the improvements and savings through the process (Lancucki, 2001).
2.2 Seiton (set in order) An application
“A place for everything and place for everything”is a quote well-suited for the second S of 5S concept
(Peterson and Smith, 2001). It focuses on segregation of things and effective storage
(Harrington, 2000). Activities included in this are labeling each item, using color for
quick identification, storing similar items together, storing different items together,
putting names and numbers on everything, painting floors and using a rack or shelf and
shadow boards for tools. Arranging items in the right place will make jigs, fixtures, tools 75
and other resources detectable, noticeable and easy to use (Dudek-Burlikowska, 2006;
Lancucki, 2001).
when the third S is implemented (Peterson and Smith, 2001; Harrington, 2000).
High-quality work is achieved. A clean and organized work area itself acts as a
motivation factor for the employees. Every employee enjoys his/her work in a clean and
healthy environment which boosts up his/her confidence (Dudek-Burlikowska, 2006).
People have to make the third “S” as a habit. They have to maintain cleanliness without
being told to do so. Zone-wise responsibilities should be given to the employees. Some
standards have to be followed to ensure that people do the cleaning effectively
(Lancucki, 2001).
3. Methodology
The scientific instruments manufacturing industry at Ambala has been selected for the
5S implementation. The industry is decade-old and has been relied upon using the good
old manufacturing technologies and management concepts. Now as the market is
becoming volatile and more competitive, there is an urgent need for the industry to quit
old manufacturing techniques and respond to the changing environment. There is also
an urgent need for the industry to get competitive enough for its survival. The aim of the
IJLSS research is to assist a scientific industry to improve overall effectiveness. Like many
6,1 new systems, resistance is seen at first. It is how you handle the implementation process
and resistance that can have an impact on your success. As expected, the organization
has more resistance at the start trying to implement 5S. The three main obstacles
observed were not enough time, lack of top management support and resistance to
change. It was hard to convince the team because they thought it was more work for
76 them. These obstacles were overcome by training the team and showing them the
benefits on an individual level. Top-level management also get convinced when they
learn about the audits and how we can measure 5S success through it. The method
adopted to implement 5S was selecting target areas like a shop floor. Shop floor was
picked because it allows people to actually see results in a shorter period. Having the
right supplies on-hand and ready to go at all times is essential to sustaining a 5S system.
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The most common supplies listed by the respondents included training materials, label
makers, sign holders, colored tape, floor tape, red tags, shadow boards, camera (for
before-and-after photos), bins and holders. After visiting the shop floor, it has been
found that, there were many opportunities to improve the shop floor. There were some
observations made after visiting the shop floor. Figure 1 shows a cause-and-effect
diagram for an unorganized shop floor:
• Workplace is disorganized; materials are laying all round.
• Cannot find things or “lost” or misplaced material or equipment.
• Lack of housekeeping.
• No visibility of the process.
The data are collected in the organization using the following methods:
• direct observations;
• participative observations;
• documentary analysis; and
• semi-structured interviews.
Material Machine
Problem identification
4. 5S implementation
4.1 Sort implementation action plan
The goal is to eliminate nonessential items from the workplace. Items are “red tagged”
and stored in a local red-tag area for a specific period, typically five days. If not
reclaimed by the work group, items are then moved to one of the company’s central-red
tag areas. Here everyone can shift through the items to see if there is anything they need.
When items have been in the central area for a specific period, the company disposes of
them through resale, donation, recycling or trash. Table I represents before-and-after
pictures of sort implementation.
State
Conditions Unneeded equipments, tools and furniture Unneeded equipments, tools and furniture
are present are eliminated
Unneeded inventories, materials or parts Unneeded inventories, materials or parts
are present are not present Table I.
Many other useless things are present Many other useless things are removed Sort implementation
IJLSS look for ways to reduce sources of waste and error as well as to make the workplace more
6,1 visually instructive. The team brainstorms potential solutions, with special emphasis on
using visual resources to achieve improvement. Be sure to get feedback and approval
from stakeholders (production, maintenance, safety, management, etc.) before making
changes. Table II represents before-and-after pictures of sort implementation.
We understand that it is not always easy to calculate savings, but this may also be a
78 reason that the largest obstacle in implementation is management buy-in. If we cannot
convert improvements to a rupee value, management will lose interest in implementing
the 5S system. Thus before implementing set in order activity, a time– cost analysis was
performed. It was observed that workers were spending average of 30 minutes/day in
search of a tool when there was no shadow board in the making. After providing shadow
board for the tools, average time observed was only 5 minutes/day, thereby saving lots
of money. Figure 3 represents the tool searching time.
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State
Conditions Operators were placing the tools here and Tools were given a proper place
there Workers don’t need to waste their
Table II. Operators wasting time searching for productive time in search for tools
Set in order tools Damage to tools was prevented
implementation Tools are prone to damage
Figure 3.
Tool searching time
4.2.1 Cost analysis An application
Worker pay per month ⫽ Rs. 8,000 of 5S concept
Average working hours per day ⫽ 8
Average labor rate per minute ⫽ 8,000/(30 ⫻ 8 ⫻ 60) ⫽ Rs. 0.55
Saved minutes/day ⫽ (30 ⫺ 5) ⫽ 25 minutes
Total money saved/day ⫽ 25 ⫻ 0.55 ⫽ Rs. 13.88
Per month saving ⫽ 13.88 ⫻ 30 ⫽ Rs. 416 79
member should be equipped with adequate cleaning supplies that have been tested to
make sure the solution will not harm any equipment or work areas. Teams can clean
things such as equipment, tools, work surfaces, desks, storage areas, floors, lighting and
anything else that affects overall cleanliness. A team may also paint or coat work
surfaces, equipment, floors and walls. Treat cleaning as an inspection process. Use it to
identify even tiny abnormal and pre-failure conditions. Working in a clean environment
enables workers to notice malfunctions in equipment such as leaks, vibrations,
breakages and misalignments. To make sure everyone participates and works together,
each team should establish a regular schedule for routine cleaning as well as deep
cleaning. Once the work area, tools and equipment are clean, they need to be kept that
way. Table III represents before-and-after pictures of sort implementation. Table IV
represents cleaning schedule performed by different workers.
State
Conditions Material lying on the floor Material placed in bin Table III.
Material gets dirty and chances of rusting Chance of rusting decreases and material Shine
increases does not get dirty implementation
IJLSS can be accomplished by visual controls such as color-coding, flowcharts, checklists and
6,1 labeling to help reinforce a uniformed approach.
4.4.1 Standard operating procedures. Standard operating procedures (SOPs) are
documents which contain instructions, steps to be followed and descriptions indicating
how a task must be performed accordingly. They describe the easiest way of doing the
job to achieve quality requirements as well as the safety one, without any risk or injury.
80 They also specify which materials and tools are necessary to do the job. Using them, the
workers themselves can control the job efficiency and improve their performance. They
contribute to assure the results foresightedly. They are proved to be a very important
tool to improve productivity; reduce faults and mistakes; and decrease time, energy and
material wastefulness. SOP for one sample product has been shown in Table V.
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Monday Mr A Mr A
Tuesday Mrs B Mr B
Wednesday Mr C Mr C
Table IV. Thursday Mr D Mr D
Weekly cleaning Friday Mr E Mr E
schedule Saturday Mrs F Mr F
been reviewed for 20 weeks and the forms have been filled as a result of the weekly
routine controls. Scores of each week are summed up, so weekly total assessment
scores are obtained and the assessments are made through reflecting the weekly
scores on the graphics. To provide proper understanding of 5S weekly score
calculations, 5S control list of Week 6 has been given in Table VI and scoring section
has been given in Table VII as examples. In the study, the data on these forms have
been used and the analyses are performed through observing the applications
within the company. Five assessment questions have been prepared and the 5S
assessment form has been prepared. For answers to be given to these questions in each week,
assessment scores as 0 ⫽ Very bad, 1 ⫽ Bad, 2 ⫽ Average, 3 ⫽ Good and 4 ⫽ Very good
have been determined.
4.6.1 5S audit results. In Figure 4 it has been observed that from Week 1 to Week 13,
the curve is vertical, that means till Week 7, sort activities are accepted as work
discipline by the personnel of the company. From Week 14 to 17, fluctuation is observed.
In this period, sort activities are not performed well, reasons being the increased
workload in the company during the same dates. In Figure 5, up to Week 8, set in order
activities are performed very well. Fluctuation from Week 9 to Week 16 is observed, but
this fluctuation is not on the higher side. Momentum is regained after Week 16. Thus, set
in order activities are taken as a continuous habit process.
In Figure 6 it is shown that shine activities, begun through the removal of water dust,
lubricants, etc., from the workplaces and environment, have been continued by the
personnel of the company in a systematic and regular manner during all 20 weeks. The
increase in the workload following Week 14 has been effective in the increase of the dirty
conditions in the workplace. But after Week 17, again a positive improvement is seen,
and now shine activities are taken as a habit by the personnel. In Figure 7 it is observed
that standardize scores had a stable process from weeks 4 to 15 and from Week 16 to 20,
the success level increased in a rapid manner. Increase in standardize activity reflects
that rules are very well-accepted in the company and 5S activities are applied in a very
well manner. As it can be seen from Figure 8, the curve of sustain scores is vertical till
Week 8 and after that almost a plain line is observed from Week 9 to 20. It shows that 5S
activities are performed by the company with full commitment and with proper
discipline, thus resulting in acceptance of the 5S system.
The results of an audit are most commonly shown using a bar chart. These can
quickly be created using a software program. The results of the actual audit,
IJLSS Score
6,1 5S No. Check point General assessment criteria 0 1 2 3 4
11 11 8 7 8 11 45
12 11 7 6 8 11 43
13 10 7 6 6 12 40
14 5 6 3 6 12 31
15 5 6 3 6 11 31
16 5 6 4 10 11 36
17 5 11 4 11 11 42
18 11 11 8 13 11 54 Table VII.
19 12 11 8 13 11 55 5S weekly appraisal
20 12 11 8 13 11 55 scores
Figure 4.
Sort score variations
improvement opportunities and the charts should be placed on display in that area. The
bar chart has been shown in Figure 9. Further, one sample check sheet has been shown
of Week 6 in Table VI. 5S activities total score from Week 1 to 20 has been shown in
Table VII.
IJLSS
6,1
84
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Figure 5.
Set in order score
variations
Figure 6.
Shine score
variations
85
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Figure 7.
Standardize score
variation
Figure 8.
Sustain score
variation
proud of my workplace. So overall they were happy from the results they achieved
after implementing the 5S system. They promised to make 5S as a habit so the
organization is benefitted from it.
6. Conclusion
The 5S event was a part of the lean initiative at the manufacturing facility. Several
changes were made to the operating procedures, tool organization, cleaning schedules
and material handling.
The first phase, sort, resulted in removing unwanted items, broken tools and
cabinets, unused parts and scrap materials. Unused inventory was returned to
IJLSS
6,1
86
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Figure 9.
Total 5S score
(Week 1 to 20)
purchasing, rarely used tools and items were assigned a new location and scrap items
were discarded.
The second phase, set in order, resulted in several changes in the organization of the
workplace. Each of the workstations received their own set of tools. All the tools were
color-coded to their respective workstation. All equipment had specific locations.
Trashcans and other items on the floor had floor markers to indicate their locations. All
tools and hoses were removed from the floor and were placed on clamps. Commonly
used parts were placed in bins on every workstation.
The third phase, shine, resulted in removing scrap, dust and other unwanted items
from each workstation. This initial clean-up helped to visualize other issues clearly.
The fourth phase, standardize, resulted in developing SOPs for the employees in the
assembly area. Some of the standards developed were:
• Each worker should use the tools assigned to him and put back the tools in their
allocated location after use.
• No units should be placed on the floor.
• Anytime a tool is missing, it should be immediately reported to the supervisor.
The fifth phase, sustain, resulted in the assembly employees conducting periodic audits
to monitor the changes made through 5S in the assembly area. Once a week, the
activities needed for continuous improvement and the audit results were put up on an
electronic notice board.
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