Lean Manufacturing in Simple Terms: the 5S Project

Here's the scenario. You walk into a place of business for the first time, to inquire about the possibility of having something built or repaired. You look around and see piles and piles of disorganized materials or parts. The counters are dusty, only half the light fixtures work, and the floor hasn't been swept since Carter was president. Besides not wanting to breathe the air in the room, you are probably considering an immediate retreat, with plans to take your business elsewhere. Your gut feeling about the quality of work that is done in that mess is probably correct. Disorganization does not lend itself well to quality work, and therefore is not a part of the lean manufacturing process.

Lean manufacturing methods include what is referred to as a 5S system, designed to organize a work area, and keep it organized on a sustained basis. What does each S in the name "5S" stand for? We have to give credit to our Japanese friends, who have for many years been the pioneers in lean manufacturing processes. Each S stands for a different Japanese word of instruction which, when used in the correct sequence, will add efficiency by the creation of a tidy work station. This can be used in any facility. (I even used it for the work bench in my garage.) Let's cover each S, and see how it can help.