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5s system in production. Japanese production management system "5S". Formation of habits and their improvement

The 5S system is one of the key tools of lean manufacturing, aimed at increasing safety, efficiency and productivity in the workplace (workspace). Due to its simplicity and efficiency, it is often the initial step in improving a production system. At the same time, the implementation of this methodology creates a new production culture that allows for qualitative changes in the organization.

The name of the method comes from 5 steps, each of which begins with “C”. Since the system was invented in Japan, the original names read something like this: Seiri, Seiton, Seiso, Seiketsu, Shitsuke. Later, 5 stages of implementation were translated into English: Sort, Straighten, Sweep, Standardize, Self-discipline, and Russian. One of the Russian translation options: Sorting, Self-organization, Radiance, Standardization, Improvement. Due to the presence of Russian translation of the stages, the name of the system can be found both in Latin (5S) and in the Russian version (5C).

It is noteworthy that a similar system - CANDO (Clearing, Arrangement, Neatness, Discipline, Organization), which appeared in the USA much earlier than 5S, is less known and widespread these days. According to some sources, CANDO is one of the lean manufacturing principles that the founder of the Toyota Production System borrowed during a visit to the Ford plant.

First step of system 5S – Sort

At this stage, all activities come down to identifying the tools necessary for the job and removing all unnecessary, faulty or unused items. Why is this being done? To increase safety in the workplace, standardize the work performed - accordingly, increase productivity and quality.

Lean practitioners call this step the most difficult, since recognizing that items that have been on hand for a long time are no longer needed is not so easy for most people. Psychologically, this requires abandoning the usual order, formed over years of work, and accepting the new, unknown, often imposed from the outside.

In order to overcome resistance at this stage, three techniques are most often used:

Provide training in the principles of lean manufacturing and the 5S system.
Involve employees in the process of implementing the 5S system at their immediate workplaces.
They create a “Red Tag Area” - quarantine for items that are not used in the workplace on a daily basis, but for one reason or another cannot be removed immediately.

Second step of system 5S – Self-organization or systematization

As lean manufacturing practitioners say: “everything has its place, and everything is in its place.” This stage is aimed at the most rational placement of items necessary for work in the work space. The more often an item is used, the closer and more accessible it should be located. The rarer it is, the greater the chances of finding it outside the workplace, for example, in a closet or on a common stand.

Why is this being done? Again, safety, productivity and quality. A conveniently located item will ensure workplace ergonomics and intended use. Those tools that are used less frequently should be placed in the shared field, which will significantly reduce their required number.

The main techniques of this stage of the 5C system are various visualization options: marking, zoning, outlining, the “shadow” method, etc.

Third step of system 5S – Shine or keep clean

This stage is aimed at creating conditions for maintaining the cleanliness of the workspace. Of course, this involves tidying up and cleaning. But the third step of implementing the 5C system does not end there. It is necessary to identify sources of pollution - understand the causes and develop an action plan to eliminate them.

Also at this stage, cleaning schedules and standards are developed (who, how often and with what?), as well as the equipment necessary for these purposes is provided.

Fourth step of system 5S – Standardization

Standardization involves measures to consolidate and maintain achieved results. For these purposes, organizational standards are being developed that, in a concise and visualized form, establish rules regarding the arrangement, visualization, cleaning, zoning and other parameters of workplaces.

In addition, this stage involves the creation of a system of control mechanisms, most often 5C audits. Why is this being done? To prevent the system from gradually “sliding down” to its original state.

Fifth step of system 5S – Improvement

What is the easiest way to ensure that your results are retained? Only by continuously improving the workspace through the efforts of all employees: every employee, every day, everywhere!

At this stage the following applies:

Ensure that staff are informed about the status of the 5S system deployment process, audit results, identified problems, etc.
Provide integration of the 5S system and the system for submitting proposals for improvements.
Provide integration of the 5S audit system and employee bonuses.

5S system

In Japan, a systematic approach to organizing, putting things in order and cleaning the workplace arose in the post-war period, more precisely, by the mid-50s of the twentieth century. At that time, Japanese enterprises were forced to work in conditions of resource scarcity. Therefore, they developed a method for their production in which everything was taken into account and there was no room for any waste. Thus, the 5S system was created. 5S- workplace rationalization system. It was developed in post-war Japan by Toyota.

5S is a workplace organization system that can significantly increase the efficiency and controllability of the operating area, improve corporate culture, increase labor productivity and save time. This is the first step towards creating a lean enterprise and applying other tools of the Toyota management system.
5S is five Japanese words:
- · Seiri (KhyAn) “sorting” - a clear division of things into necessary and unnecessary and getting rid of the latter.
- · Seiton (HyoD) “maintaining order” (neatness) - organizing the storage of necessary things, which allows you to quickly and easily find and use them.
- · Seiso (Ze’Ya) “keeping clean” (cleaning) - keeping the workplace clean and tidy.
- · Seiketsu (ZeќЌ) “standardization” (maintaining order) is a necessary condition for fulfilling the first three rules.
- · Shitsuke (bz) “improvement” (habituation formation) - cultivating the habit of accurately following established rules, procedures and technological operations.

Originally there were only 4 actions in the Japanese system. The words for these actions in Japanese begin with the letter "S": Sorting, Organizing, Cleaning (keeping clean), Standardization. Later, a fifth action was added - maintaining and improving - and completed the chain of elements that are now known as 5S.

5S now has the fundamental power to transform the workplace and involve all workers in the improvement process. 1) Sorting- means that you free up your workplace from everything that is not needed when performing current production operations. Workers and managers often do not have the habit of getting rid of items that are no longer needed for work, keeping them nearby "just in case of fire." This usually results in unacceptable clutter or obstruction in the work area. Removing unnecessary items and creating order in the workplace improves workplace culture and safety. To more clearly demonstrate how much excess has accumulated in the workplace, you can hang a red label (flag) on each candidate item for removal from the work area. All employees are involved in sorting and identifying items that:

· must be immediately removed, thrown away, or disposed of;
· must be moved to a more suitable storage location;
· must be left and their places must be created and designated for them.

It is necessary to clearly designate the “red tag zone” of items with red flags and carefully monitor it. Items left untouched for more than 30 days may be recycled, sold or disposed of. 2) Rational location- means to identify and designate a “home” for each item needed in the work area. Otherwise, if, for example, production is organized in shifts, workers on different shifts will put tools, documentation and components in different places. In order to streamline processes and shorten production cycles, it is extremely important to always leave the required items in the same designated places. This is a key condition for minimizing time spent on unproductive searches.

3) Cleaning (keeping it clean)- means ensuring that the equipment and workplace are tidy enough for inspection, and constantly maintaining it.

Cleaning at the beginning and/or end of each shift ensures immediate identification of potential problems that could interrupt operations or even shut down an entire area, workshop or plant.

4) Standardization- this is the method by which you can achieve consistency in the procedures of the first three stages of 5S - means developing a checklist that is understandable and easy for everyone to use. Consider the necessary standards for cleanliness of equipment and work areas, and everyone in the organization should know how important this is to overall success.
5) Improvement- means that following established procedures becomes a habit.

The activities underlying 5S (sorting, organizing, cleaning, standardizing and improving) are absolutely logical. They represent the basic rules for managing any productive department. However, it is the systematic approach that the 5S system takes to these activities that makes it unique.

5S goals:

1. Reducing the number of accidents.
2. Increasing the level of product quality, reducing the number of defects.
3. Creating a comfortable psychological climate, stimulating the desire to work.
4. Increased labor productivity (which in turn leads to an increase in the profit of the enterprise and, accordingly, an increase in the level of income of workers).

System steps:

Sorting. All materials are divided into:

· necessary - materials that are currently used in the work;
· unused - materials that can be used in work, but are not currently in demand;
· unnecessary/unusable - defective goods that must be returned to suppliers or destroyed.
· destroy.

Maintaining order. The arrangement of objects meets the requirements:

· security;
· quality;
· work efficiency.
4 rules for arranging things:
- · in a visible place;
- · easy to take;
- · easy to use;
- · easy to return to place.

Procedure:

1. Divide the line into zones, create diagrams and maps indicating workplaces, equipment locations, etc.
2. Determine a special group to which the cleaning area will be assigned.
3. Determine the cleaning time:
- · morning: 5-10 min. before the start of the working day;
- · lunch: 5-10 min. after lunch;
- · at the end of work: after stopping work, during downtime.

Standardization. This step involves maintaining the state after completing the first three steps.

It is necessary to create work instructions that include a description of step-by-step actions to maintain order. And also to develop new methods of monitoring and rewarding distinguished employees.

Improvement/Habit Formation. Develop a habit of maintaining the workplace in accordance with existing procedures.

Important points:

· Involvement of all employees. Teamwork.
· Monitoring the operation of equipment and the workplace to facilitate their maintenance.
· Using BEFORE/AFTER photos to compare what happened and what the end result was.
· Organizing audits to evaluate the effectiveness of the 5S program implementation.

Conclusion

5S is not just about "standardizing cleaning". 5S is the philosophy of low-cost, successful, lean manufacturing. This production philosophy/concept implies that every employee of the enterprise, from the cleaner to the director, follows these five simple rules. The main advantage is that these actions do not require the use of new management technologies and theories.

5S system

5S is a workplace organization system that can significantly increase the efficiency and controllability of the operating area, improve corporate culture, increase labor productivity and save time.

This is the first step towards creating a lean enterprise and applying other tools of the Toyota management system.

A Brief History of the 5S System

Originally there were only 4 actions in the Japanese system. The words for these actions in Japanese begin with the letter "S":

Seiri (整理)– Sorting – sorting.
Seiton (整頓)– Straighten or Set in Order – rational arrangement.
Seiso (清掃)– Sweeping – cleaning.
Seiketsu (清潔)– Standardizing – standardization of work.

5S now has the fundamental power to transform the workplace and involve all workers in the improvement process.

The 5s system includes five actions:

1) Sorting- means that you free up your workplace from everything that is not needed when performing current production operations.

Workers and managers often do not have the habit of getting rid of items that are no longer needed for work, keeping them nearby “just in case of fire.” This usually results in unacceptable clutter or obstruction in the work area. Removing unnecessary items and creating order in the workplace improves workplace culture and safety. To more clearly demonstrate how much excess has accumulated in the workplace, you can hang a red label (flag) on each candidate item for removal from the work area.

All employees are involved in sorting and identifying items that:

must be immediately removed, thrown away, or disposed of;
should be moved to a more suitable storage location;
must be left and their places must be created and designated for them.

It is necessary to clearly define the “red tag zone” of items with red flags and carefully monitor it. Items left untouched for more than 30 days may be recycled, sold or disposed of.

2) Rational location– means to identify and designate a “home” for each item needed in the work area. Otherwise, if, for example, production is organized in shifts, workers on different shifts will put tools, documentation and components in different places. In order to streamline processes and shorten production cycles, it is extremely important to always leave the required items in the same designated places. This is a key condition for minimizing time spent on unproductive searches.

3) Cleaning (keeping it clean)– means ensuring that the equipment and workplace are tidy enough for inspection, and constantly maintaining it. Cleaning at the beginning and/or end of each shift ensures immediate identification of potential problems that could interrupt operations or even shut down an entire area, workshop or plant.

4) Standardization The method by which you can achieve consistency in the procedures of the first three stages of 5S is to develop a checklist that is understandable and easy for everyone to use. Consider the necessary standards for cleanliness of equipment and work areas, and everyone in the organization should know how important this is to overall success.

5) Improvement– means that following established procedures becomes a habit

Read more about the 5s system in the books:

This book was prepared by the Productivity Press team based on the seminal work on 5S, 5 Pillars of the Visual Workplace, by Hiroyuki Hirano.

The book is recommended for anyone who wants to make their workplace more efficient, be it a workshop workplace or a bank office, an accountant's or director's office. It contains all the information you need to implement the 5S system in your company and in your personal workplace.

Most managers of large and small manufacturing enterprises complain about the lack of discipline among employees and workers, as well as the catastrophic lack of order and organization in the workplace.

Most often, this attitude of staff towards order in production is due to the lack of uniform rules within the enterprise. When the team knows that there are certain requirements for each employee, it is much easier to comply with them.

If you are determined to restore order and discipline your employees, pay attention to the experience of the most organized people on the planet - the Japanese.

Brief background

After World War II, Japan's economy was completely destroyed and the country's leadership faced the urgent question of its restoration. Since Japan is not rich in natural resources and minerals, they relied on the development of modern technologies and production.

In order to increase the productivity of enterprises, various schemes and techniques have been developed and applied. One of the most effective approaches was the 5S system, which subsequently gained worldwide fame.

Today, such a system is widely used in many areas of production. We will tell you more about it, its principles and methods below.

5S system: definition, tasks and stages

Definition

The 5S system is a unique method for optimizing the workplace, the main task of which is to reduce the costs and losses of the enterprise resulting from ineffective placement of equipment and negligent attitude of employees towards discipline and order.

This system is equally successfully used in production workshops and office premises.

The 5S system got its name because it includes 5 actions that are mandatory for every employee. This applies equally to the operating personnel and the administration of the enterprise.

Very often, the principles of this truly unique technique are exaggerated and reduced to the fact that it consists of periodically cleaning the workplace. This is wrong! There is a whole philosophy embedded in the 5S system, designed to increase productivity and reduce costs and losses of the enterprise.

Tasks

The implementation of the 5S system in production is pursued a number of important tasks, among which:

Preventing accidents at work and reducing their number;
Producing products of the highest quality, reducing the number of defective products;
Creating favorable and comfortable working conditions that positively influence the desire to work;
The desire to unify and standardize the workplace, which makes the work of workers easier and reduces the time it takes to complete tasks;
Improved productivity by reducing the time spent searching for the necessary tools within the workplace/

Stages of the 5S system

As already noted, the 5S system consists of 5 steps, which explains its name. These are the following steps:

Sorting– getting rid of all unnecessary things and objects. If the workplace is cluttered, it takes a worker a lot of time to find the right tool or thing. Therefore, each employee must carefully inspect his workplace and identify items that:

absolutely unnecessary and you can get rid of them;
can be stored in specially designated places;
are actively used and should be left. For each item, a specific place must be allocated where it will always be located.

Every item in its place. There are four basic rules how to rationally distribute objects within the workspace:

the object is in the field of view;
the object is easy to reach and take;
easy to use;
the ability to easily and quickly return an item back to its place.

Keeping it clean– Each employee is responsible for maintaining order in his or her workplace. Employees should regularly check whether things are in their place, prevent clutter and disorganization of the workplace;

Process standardization. The rules and requirements for the organization and content of the workplace must be fixed and documented in writing, in the form of a set of rules or instructions that every employee must know;

Improving organization and discipline. Regularly tidying up your workplace should become a habit and be done almost automatically. Also, workers should make suggestions regarding the improvement and improvement of the 5S system;

All of the above actions logically follow from one another. They are the basis for effective management of any area of production, and the systematic approach that the 5S system assumes makes it possible to optimize work processes, aiming them at a high level of effectiveness.

Everyone knows the so-called “Japanese quality”. Have you ever wondered why such a small country is ahead of its competitors? First of all, it is the attitude towards work. The Japanese don't have small things. They have a special, serious attitude to every operation, to every detail. Even maintaining order in the workplace is carried out according to a special 5S system. Now this system is being implemented in production by leading enterprises in different countries. You may be wondering why the 5S production system is being discussed on a website about home economics. This is not surprising. it is so versatile that it can also be used in the home (of course, adapting it a little to suit yourself).

What is the 5S system

The 5S system is one of the links in lean manufacturing. This is a system of organization, equipment, equipment of the workplace and methods of maintaining it in working order.

When I studied this technique, I constantly had thoughts about some of its similarities with the Flylady and Sluts Anonymous systems. But the 5S system turned out to be more concise and understandable. It turned out that this technique can be applied to any area or room with a specific function - cooking, working at the computer, doing homework, relaxing or playing with toys. From now on we will simply call these different places zones.

Stages of the 5S system

The 5S system is so named because it consists of 5 stages, the names of which in Japanese begin with the letter S. Similar names can also be found in Russian and English.

Seiri – Sort – Sorting
Seiton – Keep order – Set in Order
Seisō – Keep It Clean – Sweeping
Seiketsu – Standardize – Standardizing
Shitsuke – Improve – Sustaining the discipline

I will try to immediately adapt the steps for household use.

Stage 1 – Sorting and getting rid of unnecessary items

At the first stage, it is necessary to remove from the zone everything that is considered superfluous and unnecessary in this particular zone. For example, you don’t have to have a dozen pots in the kitchen. Choose the ones you use most often and are the best size for your family. Fiction also has no place in the kitchen, there is no need to store a vacuum cleaner in the bathroom, and there is no need to store a laundry basin in the nursery (unless this is a storage area specially designed by you for these items).

The remaining items, tools and equipment must be divided into those that are constantly used and those that are used periodically.

This stage is very similar to Decluttering from systems and (read articles and).

Stage 2 – Maintaining order

At this stage, it is necessary to allocate a specific storage location for all the necessary things and items that we have identified as being used constantly. So that these items are:

easy to find;
they were easily accessible;
they were returned to their place without any problems.

The rest, rarely used things should be put away in the same area, but further away: in the upper or distant cabinets, on the mezzanine.

In production, the stage of creating order is brought to perfection. There, at a glance, you can determine which tool is missing or is in the wrong place.

The principle of this stage is a place for everything and everything in its place.

Stage 3 – Keeping it clean

The third stage implies that the area itself and the things in it must be clean, in good working order and ready for use at any time.

It is necessary to consider the frequency of cleaning and checking the functionality of the equipment.

Make sure the area is equipped with receptacles for trash and waste.

Stage 4 – Standardization

Standardization refers to the drawing up of plans and instructions for compliance with the previous stages. This is done to ensure that all family members understand and comply with the principles of 5S.

I will give examples.

For a child (and not only) you can draw up a schematic action plan during cleaning.

You can make inscriptions on shelves, drawers, containers. To make it clear what should be stored in them. Then your husband will stop asking where his socks and underpants are (not all husbands are like that, of course), and your children won’t run around asking where to put this or that item.

Hang the instructions for using the washing machine next to it. And any family member can easily use the washing machine and select the correct washing mode.

You can take a photo of a cleaned room, shelf, cabinet or specific area, print this photo and place it in the right place. And if reality differs from the model, then it will be clearly visible what needs to be changed, removed or corrected. There will be no questions about what else needs to be removed.

Draw up rules for “working” in the zone. Not necessarily in writing. The main thing is that all family members know about them and comply with them. But there is a rule that seems to be the most basic, but for some reason everyone ignores it. Then it makes sense to print it out and hang it in the right place. For example: “When you eat, clean up after yourself,” “You come from the street, clean your shoes.”

Stage 5 – Improvement or Self-Discipline

At the last stage, you can already check the system in action and change it to suit your needs and requirements. Perhaps the initial developments were not entirely convenient for you, and in the process of work and life you have the opportunity to correct them.

The “Problem Analysis” method works well at this stage, with the help of which you can identify the weak points of the system and places where the system needs to be implemented. Perhaps you often look for your house keys, car keys, or remote control. Then you need to think about where to store keys and remote controls for equipment (you can read,).

Another small method is “Movement Monitoring”. Keep an eye on your family. Some of them, while doing work, use certain objects, bringing them each time from a different place. Record such moments (in memory or on paper) so that later, when analyzing the system, you can move objects directly to the desired area or nearby.

It is necessary to ensure that family members comply with all the principles of the 5S system so that it becomes a habit.

For more motivation, come up with rewards for keeping your room in order and for following the 5S principles. Such incentives will especially affect children.

Conclusion

If you implement and follow the Japanese 5S system at home, you will make life much easier for yourself and your loved ones. You will avoid unnecessary quarrels and insults. Your home will always be clean and tidy.

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