Understanding the 5S Methodology: A Cornerstone of Lean Manufacturing

Maximizing efficiency is a key goal for any manufacturer. One of the biggest trends to come out of the pursuit of productivity is lean manufacturing, but the concept’s popularity can cloud its meaning. The lean philosophy involves many terms that have become buzzwords in the industry, and the five “S” principles are among the most significant examples.

The 5S methodology is central to lean production, so any manufacturer hoping to go lean must learn what these concepts mean. Here’s a closer look at these steps and how to implement them.

What Are the 5 Ss of Lean Manufacturing?

5S lean manufacturing began with the Toyota Production System (TPS), and because Toyota is a Japanese company, all of the Ss originally stand for Japanese words. However, as lean principles have caught on, professionals have since translated them to equivalent English “S” words.

Sort (Seri)

The first “S” is for the Japanese word “seri,” which many interpret as “sort” in English. This step involves sorting through a workspace to remove anything not immediately relevant to production, in line with the lean goal of eliminating waste.

Clutter makes mistakes more likely and can take up valuable floor space that could serve a value-driving purpose. So, by clearing anything but what’s absolutely necessary from a station, the TPS paves the way for more accurate production and a greater return on investment for the facility.

It’s important to remember that sorting an area does not mean disposing of all unneeded items. Some clutter may be useful elsewhere or will be relevant at another time. Instead of throwing everything away, set it aside to go through and reorganize, reassign, store, recycle or dispose of as needed.

Set in Order (Seiton)

Next comes “seiton,” which English-speaking organizations often translate as “set in order” or “straighten.” The goal here is to organize the remaining assets from the first step into the most logical and efficient order and location possible.

Placing tools in easy reach of workers, each in a designated position, is a common way to implement this step. However, lean manufacturing initiatives should also consider larger workflow changes. Using an L-shaped warehouse layout, for example, enables shorter travel times and less congestion than a standard, U-shaped organizational structure.

Remember that some sacrifices are inevitable. It’s impossible to keep all items or assets within the same distance of a station. The solution is to identify the most commonly used objects and prioritize keeping these as close as possible.

Shine (Seiso)

The third “S” in 5S lean manufacturing is “seiso” or “shine.” As the name suggests, this step is all about cleanliness. The TPS holds that a cleaner work environment is both better for workers’ well-being and maintenance, as it makes it easier to spot equipment issues.

Regular cleaning is key to complying with regulatory standards, and earlier machine fault detection can reduce repair costs. The Environmental Protection Agency also highlights that this step reduces energy and material waste by preventing defects from contaminant accumulation.

Many organizations apply this step by creating a cleaning checklist for employees to follow at the end of their shift. Periodic inspections are another common approach, as some cleaning needs may not emerge at regular intervals and may require extra attention.

Standardize (Seiketsu)

The fourth step, “seiketsu” or “standardize,” is less of a follow-up to the previous three and more of a guiding principle for them. By standardizing policies and procedures for production, organization and cleaning, manufacturers ensure they’re repeatable, which has several benefits.

First, standardization makes errors less likely, as it removes some of the need for expertise and interpretation. Following consistent steps is easier than applying the ins and outs of an optimal workflow without such guidance. Standardized processes streamline training for the same reason.

Standardization works best when steps are simple and easy to remember. Auditing workflows to look for what employees already do can help, too. Any consistencies between different employees may reveal what feels most natural or common shortcomings that standardized alternatives must address.

Sustain (Shitsuke)

Finally, 5S lean manufacturing follows “shitsuke,” which Western organizations often translate as “sustain.” This involves two key principles — adhering to the first four Ss over time and embracing a culture of continuous improvement.

The first half largely revolves around effective training and monitoring. Employees will only follow protocol when they understand it well, including the reasons why they should follow these specific steps. Ongoing inspections and tests to promote engagement and catch noncompliance early are also crucial.

The second half is easier to miss and often harder to adopt. A true 5S philosophy involves always looking for areas of improvement, even when that means changing what’s standard in the workplace. Encouraging employees to posit ideas and share their experiences is a good measure, as is gathering as much workflow data as possible.

What Are the Benefits of 5S Lean Manufacturing?

Following these five lean manufacturing principles has many financial benefits. The first two Ss can reduce inventory costs and maximize profit potential by removing unnecessary items from factory floors. That, in turn, enables just-in-time manufacturing, which can improve cash flow and flexibility in many cases.

A cleaner, more organized workspace is also safer. In addition to protecting employee health and well-being, better safety means higher uptime and fewer losses from accidents.

Production errors and bottlenecks also become less likely when adhering to 5S lean manufacturing. Related costs and losses fall as a result, leading to higher relative profits for facilities that embrace these steps effectively.

The extent to which manufacturers experience these benefits can vary. Implementing each phase of the 5S methodology can be challenging, and it’s possible to go too far and remove some “wastes” that are actually needed for flexible production. A spirit of ongoing review and optimization can help, and smart technology often improves lean production, too.

Lean Manufacturing Is the New Norm

Lean manufacturing practices have become an unofficial standard in many production circles. Organizations must learn how and why these principles work to keep up. Learning about the five Ss is a good first step.

Once business leaders know these core lean philosophies and understand how to implement them, they can create a more agile and organized workplace. Doing so can unlock tremendous long-term advantages.