What is 6S in manufacturing? The meaning, benefits, and recommendations
This procedure enabled the Japanese company to produce higher quality products faster with less waste and inventory than the competitors. So, what are the core principles of the 6S in manufacturing?
What is 6S Before explaining 6S in manufacturing, we need to refer to 5s lean management as the base of the principle. It is a set of five steps to ensure proper organization of items and working areas to save costs, reduce waste, improve workplace management, and increase productivity. The 5s principle is most beneficial in scenarios where a company has to deal with complex working processes and asset management , therefore, it is mostly used in manufacturing.
In the 6S concept, we add safety as the sixth step, which concentrates on ensuring workplace safety and risk assessment. Therefore, manufacturing companies use the 6S to achieve an overall improvement in efficiency, product quality, a satisfaction of employees, and mitigation of safety risks. What are the benefits of 6S in production? Implementation of 6S in manufacturing can lead to a number of important benefits, and manufacturers use the methodology to solve some of the most critical pain points.
The standardized management of items and workplace helps in achieving: Costs savings and better waste managements The 6S helps to predict and schedule the maintenance of the tools, get rid of unused items, efficiently use components with closing shelf life e. This practice allows for investments, orders, and costs optimization. Higher efficiency and fewer machine downtimes Thanks to the effective organization of work items, managers and employees have a better overview of what equipment they use, when, and how often.
Therefore, they can store most used components closer to a shop floor, order missing equipment in advance, or integrate predictive maintenance to prevent machine breakdown. Production quality increase When work area is clear, the workplace is safe, and components are on reach, manufacturers can focus more on the quality of assembled products.
If using inspections software to follow 6S manufacturing , it is easier to integrate it also for quality audits. Less stressful environment for employees and better cooperation Properly integrated 6S workplace organization includes documentation, guides, and manuals for employees. Knowledge turned into step-by-step workflows enable workers to follow the standards easier and ensure they follow the best practice.
The practice eases the stress load and also allows for improved onboarding as manuals and guides are immediately available to newcomers. Workers feel safer, which further leads to improved focus and lower stress. It is a critical topic nowadays, often required by legal regulation. Safety precautions should be one of the most important processes integrated into the day-to-day operation, especially in more hazardous environments.
Like manufacturing factories are. With the safety step in 6S lean management, you want to make the workplace safer for workers. Mitigation of hazards and near-misses starts with their identification. Document all safety risks during every stage of the 5S management and you are on a good way to improve the working conditions.
Afterward, set up regular safety checks and preventive measures to keep the hazards as low as possible in the future. Sort Seiri Do you know where are all the tools and components that workers use located? The fundamental process of the 6S, sorting, is specifically designed to find out all this information.
You need to identify the items placed in the working area to decide what to do with them. Optimize the process by tagging the equipment with color tags or with inspections software.
Is the item unnecessary? Tag it with the red for further processing. Is the equipment misplaced and should be located in a different work area? Choose a different tag to visualize the difference. Equipment Maintenance Checklist Download template Set Seiton After sorting out which items you need to keep, relocate, or throw away, it is time to do so. Organize the workplace to be as functional as possible. Frequently used equipment should be quickly accessible for workers. Also, it is beneficial to document the process right from the beginning to maintain efficiency.
It is harder to write down manuals and guides afterward. Sometimes, you can forget about a key step that can present a risk for the next inspection. Or you will have to start from the beginning as the process will be incomplete.
Again, you can keep the guidelines on paper, in excel sheets, or also consider to utilizing mobile forms. Choose whichever fits your operation the best. It is time for a proper cleaning procedure to make the area neat and tidy. You should set up a regular cleaning schedule to ensure it is not just a one-time action, but a standardized process followed in the future. Standardize Seiketsu This is the time where you can take advantage of the documentation and notes you made in the previous steps.
It is necessary to standardize everything that you conducted during the sorting, setting up, cleaning, and safety phases. That means you need to create some rules and instructions for conducting the steps regularly. It may be the hardest step in 6S, but when you carried it out thoroughly, you will benefit from the process in years to come. Write down instructions for humans and not in a vague official language. The better you write the guide, the easier it will be to follow.
Sustain Shitsuke If you have completed all the steps above, great. You are on track to implement 6S lean management in your company. But consistency is king here. You need to follow up in the coming days, weeks, months, and years to reap the benefits. Set up and schedule regular inspections for 6S management and make it a routine for your team. Make it a part of the operation. Assign individual tasks to specific employees. You can help workers and managers with checklists to keep up with all the steps.
Also, talk to your employees about the benefits that 6S management of the workplace brings. When they are aware of the advantages, they will be eager to proceed with the inspections regularly. Nowadays, safety is at the forefront in the majority of industries. While 5S proved its benefits over decades, if you can integrate safety precautions into the steps of lean management, you should definitely go for it.
Starting with a 6S program in your company The 6S methodology proved to be a very effective in manufacturing over years. By implementing 6S principles and practices, you can create high-quality products with lower budget, produce less waste, and save more time. If you want to proceed faster, an inspection software can automate various processes within the 6S procedure thanks to checklists, mobile forms, inspection reports, or job assignments.
For example, with a tailor-made 6S checklist, your employees can check if all necessary steps were completed correctly and in the right order.
You can find free manufacturing checklists in Resco template library. Digitalization of these processes also enhances data collection standardization and offers real-time updates for managers and supervisors, who can then further streamline required procedures.
You can start with a free day trial of Resco Inspections that comes with a free OSH risk template , you can easily customize for safety inspections in 6S methodology. Share: Follow our blog Enter your email address to follow this blog and receive notifications of new posts by email.
Thank you for signing up for blog update notifications.. Update your preferences by clicking on the preference center link in any email.
5S Audit Checklist Form Template [Best Practices and Free Sample Form]
It is based on the 5S principles which we will discuss shortly. A safe and productive workplace needs structure and discipline. That is the crux of the 5S audit. It provides a framework that defines efficiency and organization for the systematic working of a workplace.
The very fact that most audits, especially the ones based on simple checklists, depend on the auditor himself; the 5S organization checklist make the results of the audit a lot more accurate and meaningful. Measuring the Organization level The 5 S Principles include 1.
Cleanliness, 2. Robustness of the housekeeping procedures, 3. Degree of Standardization 4. Organizational approach 5.
Tagging frequency The 5S audit form itself consists of 7 points and should not take more that 7 minutes for completion. Thus, every worker must have the same understanding regarding the 5 phases of workplace organization : 1.
Sort— Sorting and removing what is unnecessary. Only things needed in the workplace are tools, parts and instructions to do the job. Systemize-Creating a systematic visual scoreboard so that items are set in order and there is a place defined for everything. Cleaning helps reveal problems and also can be used as a method of inspection. Standardize— Routine cleaning of this sort is incorporated as a way of life.
Preventative maintenance is routinely scheduled and performed especially by people who know the work center well. Benefits of 5S An important advantage of using the 5S to make the work area clean is that potential problems are easily revealed. Second advantage of the 5S audit form is the reduction in the amount of time wastage for looking for tools, materials and supplies etc. Regular use of the auditing of this sort can help provide feedback constantly.
This can help bring a higher degree of safety, efficiency and orderliness to the workplace. It can help assess the organization and housekeeping levels in the workplace. Success in using the 5S audit forms For more reliable and meaningful results while using the 5S audit form, the test must score multiple dimensions and include the system configuration, know-how levels, observed cleanliness results, organizational system approach, as well as the frequency of tagging.
That being said the entire 5S audit forms are particularly important to be included in every well designed lean management system.
Top 10 Warehouse Safety Checklists
Measuring the Organization level The 5 S Principles include 1. Cleanliness, 2. Robustness of the housekeeping procedures, 3. Degree of Standardization 4. Organizational approach 5. Tagging frequency The 5S audit form itself consists of 7 points and should not take more that 7 minutes for completion.
Thus, every worker must have the same understanding regarding the 5 phases of workplace organization : 1. Sort— Sorting and removing what is unnecessary. Only things needed in the workplace are tools, parts and instructions to do the job.
Systemize-Creating a systematic visual scoreboard so that items are set in order and there is a place defined for everything. Cleaning helps reveal problems and also can be used as a method of inspection. Standardize— Routine cleaning of this sort is incorporated as a way of life. Tools are kept clean and in good working order. Where possible, tools are stored in a manner to keep them clean and free from risk of damage. Paperwork is not torn, kept clean and protected from dirt. Work surfaces machines, workbenches, dies, and other equipment including electrical boxes are clean and painted.
Standard work is one of the most important principles of Lean manufacturing. Product waste e. Preventive measures have been implemented to ensure the workplace meets 6S guidelines e. The results of the previous audit are posted and clearly visible to the entire team. Areas for improvement identified during the previous audit have been completed. Tools, equipment, paperwork, furniture, etc.
Documents are labeled clearly as to contents and responsibility for control and revision. The date and revision number are clearly visible. Equipment maintenance records are visible and clearly state when maintenance last occurred and when next maintenance is scheduled. All operators, team leaders, supervisors, etc. The team took the initiative to make improvements to the workplace that was not identified during the last 6S audit.
A member of Management has participated in a 6S activity such as an audit or other activity within the past 3 audit periods. Recognition is given to teams who get involved in 6S activities.
Time and resources are allocated to 6S activities e. Equipment safety concerns are clearly identified. Safety guards are painted, in good working condition and provide adequate protection. Stop switches and breakers are highly visible and located for easy access in case of emergency.
Tripping dangers such as electrical cables, etc. Working conditions are ergonomically friendly. Tools are stored at appropriate heights; lift assist devices are provided where necessary, etc. The work environment satisfies the requirements of the work being performed. Lighting brightness and colorair quality, temperature, etc. The workplace layout accommodates easy exit in case of emergency. Walkways and vehicle paths are clearly identified and unobstructed.
Exits are clearly labeled and unobstructed. Work areas requiring personal protective equipment are clearly labeled. All personal protective equipment is maintained in sanitary and reliable condition and is properly stored in an easily accessible and labeled location when not in use. Fire hoses, fire extinguishers and other emergency equipment are prominently displayed and are unobstructed. Self Discipline levels of 5S Level 5:Focus on Prevention There is a general appearance of a confident understanding, and adherence to the 5S principles.
Information board shows root causes and action on metrics. Level 4: Focus on Consistency Follow-through with 5S agreements and safety practices is evident. Meaningful metrics are visually part of information board.
Level 3: Make It Visual 5S agreements and safety practices have been developed and are utilized. Information board is present, visible, and maintained. Level 2: Focus on Basics A recognizable effort has been made to improve the condition of the workplace.
Everything You Need To Know About the 5S Audit
Team members have knowledge of 5S. Level 1: Just Beginning Workplace checks are randomly performed and there is no visual measurement of 5S performance. Standardize levels of 5S Level 5: Focus on Prevention Everyone is continually seeking the elimination of waste with changes documented and information shared.
Level 4: Focus on Consistency Substantial process documentation is available and followed. Possible for visitors to tell what work is being performed and where in most cases. Level 3: Make It Visual Working environment changes are being documented.
Visual control agreements for labeling and quantity levels established.
5S Audit Checklist
Level 2: Focus on Basics Methods are being improved but changes have not been documented. Level 1: Just Beginning Workplace methods are not consistently followed and are undocumented. Sweep levels of 5S Level 5: Focus on Prevention Employees have devised a dependable, documented method of work area maintenance. Work area cleanliness and organization is a way of life.
Level 4: Focus on Consistency 5S agreements are understood and practiced continually. Visual controls have been established and marked. Key items to check have been identified. Level 1: Just Beginning Workplace areas are dirty, disorganized, and key items are not marked or identified. Simplify levels of 5S Level 5: Focus on Prevention Anyone can walk into the area and easily locate work by priority. Abnormal conditions are visually obvious and corrective action measures are in place Level 4: Focus on Consistency A dependable, documented method has been established to recognize, in a visual sweep, if items are out of place or exceed quantity limits.
Level 3: Make It Visual Designated locations are marked to make organization more visible. Incoming and outgoing areas are clearly marked and utilized. Level 2: Focus on Basics A designated location has been established for items according to use. Level 1: Just Beginning Items are randomly located throughout the workplace.
Sort levels of 5S Level 5: Focus on Prevention Employees are continually seeking improvement opportunities. Level 4: Focus on Consistency A dependable, documented method has been established to keep the work area free of unnecessary items. Level 3: Make It Visual Unnecessary items have been removed from the workplace. Level 2: Focus on Basics Necessary and unnecessary items are separated.
Nothing is placed on top of machines, cabinets, etc. Level 1: Just Beginning Needed and not needed items are mixed throughout the workplace. Steps to implement 5S Step1: Establish a 5S Promotion Organization There should always be some kind of organization in charge of promoting 5S implementation. Step 6: 5S Evaluation and Follow-up To prevent 5S conditions from deteriorating, periodic 5S evaluations should be initiated to check, maintain, and improve 5S conditions.
Repeating steps 4 and 5 will also help improve 5S conditions. Steps to implement Seiri What to do who does it? Identify the coordinator CEO 2. Identify the zones Coordinator 3. Identify the Red tag holding area Co-coordinator 5. Define the Red Tag Co-coordinator 6. Do the red tag all persons?
Start to Shine Steps in making a 5S Map 1. Make a floor plan or area diagram of the study area. Draw arrows in process flow sequence.