How to implement 5S and safety improvements in organisations
Step 1 – Leadership Commitment for 5S Implementation
5S is a journey without destination. It requires long term commitment from top management. Leaders should lead by example. Commitment can be demonstrated by active participation in 5S workshops, Gemba Walks, Providing timely resources, Conducting regular reviews etc.
Step 2 – Formation of Core team
Core Team comprises voluntary and authorised members whose roles and responsibilities clearly defined. Below is the example of composition of Core Team
Leader – Standardization
Leader – Training
Leader – Auditing and Assessments Leader – Rewards and Recognitions
Leader – Events and Publicity Leader – Facility Management/Resources
Core team also prepares the 5S Master Plan which will be approved by Leadership
Core Team must lead by example by implementing 5S in their respective areas starting from his/her own work desk
Step 3 – Create Small , Manageable 5S Zones
The entire organization should be divided into small and Manageable zones. Each Zones will be Managed by Zone Leader/s who have good influence on Zone activities and members
Step 4 – Train 100 % employees
All employees including Leadership team, Managers, Supervisors, Operators should be given basic awareness training on 5S. The training should be conducted by certified trainers. This training should be repeated at a defined frequency. Organizations need to ensure new employees provide 5S training as a part of the Induction program.
Core Team and Zone Leaders receive more comprehensive training covering their roles and responsibilities
Step 5 – Plan and Execute 1S and 3S Workshop
Based on Number of Zones and complexity, the time duration varies from few hours to few days. 100 % employee involvement including leadership is required for this workshop
Step 6 – Develop 5S Standards Manual & Implement 2S
This Manual should be ready before implementation of 2S.
Step 7 – Sustain through regular training, Audits, Employee Engagement events, Rewards & Recognition Programmes. 5S Standards Manual need to be updated periodically to reflect all the changes
Top Management shall demonstrate leadership and commitment with respect to the 5S implementation by
- Establishing and Communicating 5S Policy
- Assigning 5S Champion role to one of the Top Management members.
- Leading by Example – Participating in all 5S related programmes, Implementing 5S in his /her own area, Gemba Walks
- Ensuring 100 % employee involvement in 5S implementation
- Communicating the importance of 5S throughout the organization.
- Providing timely resources
- Regular Training and development of people
- Establishing rewards and recognition systems
- Periodic review of 5S progress
- Allocating time for 5S activities
Seven Steps Academy of Excellence provides training services in the field of Lean manufacturing, Lean Services, Lean Hospitality, Lean hospitals, Lean Supply Chain, Lean warehousing, Lean retain. As part of this, tools and methodologies for training includes Applied 5S, Lean Experiential Learning programmes, TPM Training, Six Sigma Green Belt and black belt training, Lean Six Sigma Yellow belt, green belt and black belt, Kanban supermarket. Apart from this, Campus to corporate programmes in precision engineering is also offered to aspiring engineering and diploma graduates through focussed skill development programme.
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