The 5S Method

In a metal manufacturing setting, the Kai zen 5S scheme, which is an array of five Japanese words beginning with the letter “S” can be implemented for the shop floor.  This scheme allows for a clean, working environment.  

The first “S” is Seiri and refers to neatness or in English can be referred to as “sort.”  The shop floor in a metal shop should always be neat.    Any items not necessary for production need to be discarded.  A method of identifying unneeded articles is by “red tagging” them, which is precisely what it means:  placing a red tag on it.  The items are then moved to a place where they can be ordered and either recycled, used elsewhere, or thrown away.

The second “S” is Seiton and refers to organization or objects being “set in order.”  The shop setting should have everything organized.    Articles must be stockpiled effectively and tagged so that employees can find them easily and quickly.  If things are out of place, this will increase production time while workers look for components. It is important that all of the “S” methods go in sequence and that this step is done after sorting because time does not need to be squandered sorting items that need to be red tagged and thrown away.  

The third “S” is Seiso which is defined as cleanliness or “shine.”  Now that everything is put away, an exhaustive cleansing of the shop needs to be done and on a continual basis in the future.  Equipment and areas should always be clean so they are functioning at their best so cleaning of areas should be done daily.  Cleaning also helps employees notice if something is not functioning correctly.  Dirt can hinder the effectiveness of a machine in a metal manufacturing environment.  

The fourth “S” is Seiketsu, which is defined as standardization.  Standardization makes sure that everyone is on the same page in what they should be working on and a standard form of procedures is always followed so that the 5S methodology is upheld.  Signs and charts can be used as reminders to staff so that they keep using the system. Roaming from the steps or standards can waste valuable time.  Prevention is important in this step so that an accumulation of unnecessary materials is avoided, a dirty work environment is avoided, and the first 3 S’s are maintained.

The last “S” is Shitsuke and is defined as sustaining the discipline and continuing with the principles of Kai zen through continuous improvement.  The goal is to make all of the S’s a practice and to not fall back on old habits and forget about the 5S methodology.  Management follow-up and constant reminders are necessary to make sure that the 5S system is a success.
Oftentimes a sixth “S” is appended for safety. This “S” would be good to add in a metal manufacturing shop due to the manufacturing equipment that is on the shop floor such as laser cutters.  Employees must be schooled in safety measures and safety obedience.

5S Methodology in Practice

At Maloya, we utilized the 5S methodology in many ways to advance our working environment.  We used metrics to evaluate efficiency and achievement in our production work environment as well as evaluated production quality levels.  We also observed benchmarks of necessary skill abilities for staff working in certain areas so that they could determine which of their staff needed more training.  The methodology let us to grow our company significantly by putting into practice the 5S system in a metal manufacturing setting.  

Marc Anderes is a co-founder of Maloya Laser which specializes in <A href=”http://www.MaloyaLaser.com”>Laser Cutting</a> and Metal Manufacturing with advanced <A href=”http://www.maloyalaser.com/capabilities_equipment.php”>laser systems</a>, servicing machinery, aerospace, medical, scientific and transportation needs.