Master point to implement 6 ‘S’ methodology

Now a day’s everyone is focused to improve processes but it’s not easy for everyone. The goal of people is to establish a world-class manufacturing system and implement lean manufacturing concepts. 6 ‘s’ implementation is a very basic tool of lean manufacturing and you start the improvement journey with 6 ‘S’.

Before you read this article review the 6 ‘S’ Implementation article and 60 Audit points for 6 ‘S’ Implementation. After the basic understanding of 6 ‘S,’ it is very important to be aware of the practical guideline for 6 ‘S’ Implementation. Review the attached 50 sequential points for the 6 ‘S’ methodology.

50 master point to implement 6 ‘S’ methodology

1. Plan training of 6 ‘S’ Implementation including workers as well as staff.
2. Decide 6 ‘S’ team formation, team leader, team facilitator, and all the premises divided into no of zones and identify zone leader.
3. Gantt chart developed plan Vs Actual.
4. 6 ‘S’ Policy developed.
5. Circulate the 6 ‘S’ Calendar and plan monthly activity before the month start and adherence it based on the plan.
6. Separate activities plan for management support required like (purchase items, stationary marking tap, shadow board, tools, table, etc.)
7. Before starting, any activity on the ground level takes photographs of all the premises where the plan to implement 6 ‘S’ is.
8. Identify red tag zone area-wise or centralized.
9. Periodically plan to celebrate red day during sorting phase implementation.
10. Maintain red tag register and update periodically basis.
11. Make a list of necessary items.
12. Separate necessary and unnecessary items and remove not needed items from workstations as well as future needed items or other department needed items put into red tag zone.
13. Plan audit of sorting phase implementation.
14. Audit reports circulate to all members, responsible persons as well as top management.
15. Plan to close all the points raise during the sorting phase audit.
16. Identify the frequency of usage items based on the necessary item list.
17. Set item-wise fixed location based on the frequency of usage. (“place for everything and everything’s in its place”)
18. Plan to item arrangement on the wall with hook, on shadow board or net board, rack, drawers and table, etc.
19. Items labeling and color code usage are very important in set-in-order phase implementation also plan to floor marking as per standard.
20. Plan to conduct an audit of the sorting and set-in-order phase.
21. Audit reports circulate to all members, responsible persons as well as top management.
22. Plan to close all the points raise during sorting and set in order phase.
23. Make a proper schedule of cleaning activities and give responsibilities area-wise. (including machinery items also)
24. Make a separate checklist of floor area and machine.
25. Developed standard procedure for cleaning and follow practice cleaning with meaning.
26. Periodically plan to organize cleaning drills.
27. Each and everyday plan to for 5 min cleaning area wise.
28. Plan to conduct an audit of sorting, set in order, and shine phase.
29. Audit reports circulate to all members, responsible persons as well as top management.
30. Plan to close all the points raise during sorting, set in-order phase, and shine phase.
31. Plan to develop standard operating procedures and work instructions and display them in designated areas.
32. Developed checklist for 6 ‘S’ routine activity.
33. Ensure the 6 ‘S’ audit score and audit schedule are displayed.
34. Plan to conduct an audit of sorting, set in order, shine, and standardize phase.
35. Audit reports circulate to all members, responsible persons as well as top management.
36. Plan to close all the points raise during sorting, set in order, shine, and standardize phase.
37. Ensure periodically developed 5 ‘S’ audit – once a month.
38. Display of area-wise responsible person and organizational chart.
39. Plan to display 6 ‘S’ best practices and reward and recognition plan for the best area.
40. Plan to display 6 ‘S’ poster slogans for 6 ‘S’ Awareness.
41.  Plan to conduct an audit of sorting, set in order, shine, standardize and sustain phase.
42. Audit reports circulate to all members, responsible persons as well as top management.
43. Plan to close all the points raise during the 5 ‘S’ Audit.
44. Developed a safety committee and periodically plan to review unsafe acts as well as conditions on the shop floor.
45. Ensure adherence to PPE at the workplace and floor to be clean without any obstacles.
46. Developed standard procedure for near miss and incidence reporting and focused on electric cable and its condition. Ensure the machine’s rotating parts and attached safety guard on parts.
47. Plan to conduct an audit of 6 ‘S’.
48. Audit reports circulate to all members, responsible persons as well as top management.
49. Plan to close all the points raise during the 6 ‘S’ Audit.
50. Maintain audit practices on regular basis.