Time and again, it has been said and agreed that Five S is a fundamental tool for all the improvements. It is a Japanese philosophy that is based on waste elimination through workplace organization. The focus is on effective workplace organization and standard procedures and processes at the workplace. Five S eliminates waste, reduces non-value adding the activity with the aim to improve quality, effectiveness, and safety at work.
These are five words starting with S in Japanese and same in English.
The Five S are as follows:
5. Self Discipline
“A place for everything, and everything in its place” is the mantra of the 5S method. Some of the benefits of Five S are as follows:
1. Improve Quality
2. Lower Costs
3. Promote Safety
4. Build Customer confidence
5. Increase equipment effectiveness and efficiency
6. Reduce Downtime
Team Faber Infinite launched a Five S implementation initiative at one of the largest HDPE and PVC pipes manufacturer in India. The objectives of the initiatives are:
Roll out the 5S program for entire Client Unit
Create the organization structure for Five S journey
Strengthen the review mechanism of Five S through steering committee mechanisms
Train the member and create champions for Five S implementation
Create model zones in the area of implementation
Demonstrate the best way to deliver PEEP in model zone
Prepare a detail action plan for all zones with target date and responsibility
So far, within short time of implementation, client team has seen tremendous benefits. Some of which are mentioned below:
• Space saving after removing ~100 Red tag items from model sub zone
• Searching time has been reduced from average 3 mins to 20 sec
• Layout has improved
• Space saving of 750 sq.ft (approx.) after scrapping 45% of items identified in the red tag registers covering 80% of the plant area.
Everyone and all types of organizations can benefit from rolling out a structured Five S initiative. Manufacturing and industrial plants come to mind first, as those are the business that can realize the greatest benefits. However, any type of business, from a retail store to a power plant — from hospitals to television stations — all types of businesses, and all areas within a business, will realize benefits from implementing a structured Five S movement.
Written By Faber Mayuri Pandya