6 ‘S’ is a basically workplace improvement tool & basic platform to build strong roots of lean manufacturing. 6 ‘S’ is very easy to understand everyone but difficult to sustain on day to day basis. The majority of the small, medium & large-scale industries not succeeding in the implementation 6 ‘S’ methodology due to some minor self-disciplinary & ignorance issues. If any organization wants to achieve excellence, the basic step is to start with the 6 ‘S’ implementation.
In this article what did you learn?
- Basic History.
- What is 6 ‘S’ – Individually.
- Overall practical implementation Steps as well as individual.
- 6 ‘S’ Implementation possibilities.
History of 5 ‘S’
5 ‘S’ Developed by: – Hiroyuki Hirano
Originated in: – Japanese Business
First Implemented by: – Toyota Motor Corporation.
Before the 5 ‘S’ Methodology invention ‘Henry Ford’ Developed the ‘CANDO’ Methodology, Its Means that (Cleaning, Arranging, Neatness, Discipline, and Ongoing improvement)
Stages of 6 ‘S’
There are several lean manufacturing tools used to improve productivity of organizational processes such as kaizen, work study, poka yoke and many more but 6 ‘S’ is the first stage to implement lean manufacturing concept in organization. After understanding basic of 5 ‘S’ history, let’s jump to the individual understanding of each stage of 6 ‘S’.
1 ‘S’ – Sorting
The first stage of the 5 ‘S’ is sorting. In the sorting phase where you want to implement the 5 ‘S’ first step is to make the necessary item list per workstation area-wise. Ensure all the unnecessary or future long-term needed items are not available at the workstation.
The question comes to mind – if remove all the unwanted or future needed items from the workstation so where we can put all the items right? so, basically each and every needed or not needed items are categorized into four parts. Review below attached detail item bifurcation of sorting phase.
Red tag zone: – red tag zone is a separate zone identified for the particular workstation to put items not needed for the current workstation, chances to the usage of such items in another workstation. Each and every item within red tag zone is maintained with log number and log number attached on each and every item with the sticker note. all the item within red tag zone is structurally maintained with red tag register.
Review and download below attached excel format of red tag register.
Periodically plan red tag review – in this exercise plan review each red tag zone in a group of workstations in charge & take needed items as per requirement & make a decision on unneeded items.
2 ‘S’ – Set in order
After understanding the sorting stage let’s time to understand the set-in-order phase and review the attached key points for implementation.
In the sorting stage, we remove all the unnecessary items from the workstation, in set in order phase we understand how we will arrange all the necessary items in such a way that easy to use all the items with respect to requirements & ensure arrange all the items in a such a way to minimize item searching time.
Set in order phase key objective is “place for everything & everything in its place”
Review the below-listed activity we need to perform in the 2 ‘S’ phase.
- The systematic arrangement of necessary items.
- Identify the frequency of needed items, make a frequency chart of necessary items & identify materials & items locations.
- Focused on visualization (color code for quick identification)
- Fixed place identified for moving, non-moving & partially moving items & types of equipment.
Review and download below attached excel sheet for maintaining necessary item list of sorting phase as well as mention its frequency of use with the fulfill requirement of set in order phase.
Review below attached chart for floor color coding as per ANSI standard. For visual management point of view it is very important to color coding, it helps to identify variations as well as abnormalities in 6 ‘S’ standard.
3 ‘S’ – Shine
After implementing two pillars of 5 ‘S’, time to understand & implement 3rd pillar. Shine means cleaning. Shine means not only following regular cleaning or housekeeping practice but in terms of cleaning with meaning.
The two more practices to be followed in cleaning with meaning.
- Identify the source of contamination.
- Identify hard-to-access areas.
Many people have a simple question about implementing the shine phase why we do clean continuously basis if the workplace or area again converts dirty, so the answer is you are required to work on the exact source of contamination.
In another way, the cleaning staff does routine-based cleaning but covered only areas that are easy to access they don’t want to focus on hard-to-access areas. One of the most important aspects during the shine phase implementation is converting hard-to-access areas into easy-to-access areas.
When we clean the area to the initial level another person can easy to inspect the area or machinery, equipment & floor area, in short, a cleaning checklist should be available in the workplace.
4 ‘S’ – Standardize
As per the above listed three pillars are most important, if the three pillars are successfully implemented on a continuous basis, then time to process standardized in 4th pillar, otherwise it’s very difficult to maintain in routine practice.
In the standardized phase majority of the focused activity is the review of sorting, set-in-order & shine pillar of each activity in detail & developed standard of daily routine practices.
In the initial case starting the shift or day in any industry takes time to implement three pillars but when we standardize processes its reduces time & becomes a part of regular practice.
5 ‘S’- Sustain
In sustain pillar, the main activity is making audit points for each 6 ‘S’ phase & audit schedule plan on regular basis & identifying opportunities for improvement areas & follow certain standardized steps to take lesser time for re-arranging all the items at the decided place.
The entire area divides into divisional areas & identify responsible person area wise & developed a 6 ‘S’ Organizational chart.
In the organization’s main entrance or shop floor main area plan to display the 6‘S’ audit score, best practices, Training & Awareness focused on making a visual workplace with a 5‘S’ Poster, slogan, etc. make a proper plan for 5‘S’ awareness including worker & staff.
What are the important parameters to be considered for the display 6 ‘S’ Board?
- 6 ‘S’ audit score.
- Training & Awareness plan.
- 6 ‘S’ best practices.
- Audit planning schedule.
- Cleaning drill & red day celebration schedule.
- Opportunities for improvements.
- Near miss & accident record.
- Safe man hours.
6 ‘S’- Safety
6 ‘S’ is recently added continuing to 5 ‘S’.
If any workstation, area, or organization successfully implemented the 5 ‘S’ methodology, its safety score of the workplace is inbuilt improved because the hazardous area is basically an Unorganized workplace with obstacles.
Review certain points attached below to maintain basic safety practices.
- Maintain the basic practice to wear PPE at the workplace.
- The floor is to be clean without any obstacles.
- Near miss & accident report recording & communication procedure.
- The safety committee developed & periodically plans reviews.
- Maintain machine condition & rotating parts as per safety guidelines.
Benefits of implementing the 6 ‘S’ methodology.
- Implementation – Sector possibilities
The majority I must tell you, each & every sector is possible to implement the 6 ‘S’ methodology because its design is based on the generalized way to implement it everywhere. I listed some sectors but they are not limited to only implementing this methodology.
- Manufacturing Sector.
- Service sector. (Banking)
- Chemical, pharmaceutical & hospitality sectors.
- Automobile sector.
- Food & dairy products sector.
- Home, Offices & Showrooms.
- Retail grocery shops.
- Consumer durables & electrical sector.
Great learning
Appreciate your explanation about the 6’S
Thank you for enlighten knowledge about 6S Methodology.