Cleanliness and order are two key factors to ensure productivity, efficiency and motivation in a factory. Keep reading to find out how the 5S methodology works and what tool Mapex incorporates to maintain it over time.
It is quite common for companies that want to enhance operational efficiency in their manufacturing plant to implement the Lean 5S method to optimize processes, eliminate waste and promote a culture of continuous improvement.
Next, we explain what this methodology consists of, what its five principles are and what challenge you may face when putting it into practice in your organization.
What is 5S?
5S is a methodology that seeks to create and maintain an organized and clean work environment over time. To achieve this, it is necessary to follow these steps:
1. Seiri (sort): differentiate between what is necessary and what is unnecessary, eliminating superfluous elements. By freeing up space in the work area, it is easier to quickly identify the tools and materials essential to carry out a task.
2. Seiton (set in order): after sorting, it is crucial to organize and declutter the workspace to minimize time searching for tools and other items.
3. Seiso (cleaning): this step promotes cleanliness and maintenance of the workspace, developing daily habits that create a safer and more pleasant environment. Regular cleaning also allows you to identify possible problems or defects in facilities and equipment.
4. Seiketsu (standardize): it implies establishing standards and procedures, developing standardized processes to consistently maintain the above 3S. This facilitates staff training and ensures continuity in the application of the method.
5. Shitsuke (self discipline): this stage encourages discipline and self-responsibility, ensuring that employees consistently follow established standards. Thus, efficiency and continuous improvement take root in the organization.
The benefits of working in a clean and orderly environment
Over the years, new S’s have been added to the original methodology created by Toyota in the 1950s (note that, originally, the method focused on only four principles: Seiri, Seiton, Seiso and Seiketsu).
In this sense, and according to Cristoph Roser in this article, “it makes no difference if you have 4, 5, 6, 7, or even 8S. These S’s are only a mnemonic to help you get your stuff in order and keep it that way. These are not a step-by-step approach, but more of a reminder.”
That being said, why will we always be more productive and efficient in a clean and orderly production plant? Let’s look at some examples:
- Having the right tools in good condition reduces defects and rework, as well as workplace accidents.
- Easy access to tools speeds up their use and therefore reduces downtime on production lines.
- During the process of cleaning and organizing a factory, we can see which tools are really necessary and which are not, optimizing storage space.
- The onboarding process for new workers is reduced because they can more quickly find and familiarize themselves with the tools and equipment needed for their tasks, distractions are eliminated, and documentation and work procedures are clearly defined.
- Systematic cleaning of machinery can help detect equipment failures that would otherwise have been missed.
How to maintain 5S over time?
Despite its numerous advantages, many companies fail to maintain the 5S methodology over time. To prevent this from happening, keep these recommendations in mind:
- Integrate 5S into a larger project of improving efficiency, safety or quality so that your employees see these practices not as isolated tasks but as activities that contribute to the overall success of the company.
- Think about where it is really necessary to apply 5S. For example, 5S is useful in work areas where many people, often on different shifts, need access to the same tools.
- Involve people from the area you are optimizing. With their knowledge and involvement, you will achieve better results and the chances of maintaining the methodology over time will be greater.
- Do not forget the fundamental role of management in complying with 5S, especially in the standardization and self-discipline stages. The responsibility should not only fall on the operators, but plant managers must periodically verify if what was agreed is being complied with or if, on the contrary, corrective actions must be implemented.
Mapex to digitize 5S audits
To the list of recommendations that we have just seen, we would like to add one more piece of advice: the creation and implementation of audits to guarantee that the 5S methodology is being carried out correctly.
These types of check-lists help you discover inefficiencies before they become real problems that affect the productivity of your factory. Likewise, they are very useful for maintaining discipline and updating standards of cleanliness and order.
Did you know that Mapex allows you to digitize these checklists? To begin with, thanks to our MES solution, at the management level, you can establish an action plan and enter and schedule the necessary 5S audits in the system.
Operators will be able to view on screen and in a 100% paperless environment the tasks that are standardized in their workplace, and pass the inspection points that correspond to them, attaching images as evidence.
Our software also records activities already carried out and provides visibility into pending checklists, results obtained and corrective actions that have been carried out.
This is just a summary of what Mapex can do to help you enhance aspects such as quality, safety and efficiency in your factory. For more information, do not hesitate to contact us through this form.
