Importance of 5S in Operations

 The 5S system of organization developed by the Japanese consists of 5 steps all starting with the letter "S":

1. Sort 
2. Systematic Arrangement ("Set")
3. Shine ("Sweep")
4. Standardize
5. Sustain

 A great explanation can be found on Wikipedia along with other websites:

5S methodology from Wikipedia


I used this system when I worked at Boeing and saw how efficiently it improved operations. (I put the quotation marks around the terms as I used them at Boeing).  We used the 5S system both in the office and in the factory.

Using it in the office I noticed a little improvement. Many of the excess file cabinets, folders, etc. were eliminated by a "sort" and this did much to clean up the office.  However over time the other four steps were not followed consistently and the effectiveness of the 5S methodology diminished.

The factory operations had much better success.  I noticed that many of the tools used by the mechanics were mounted in boxes in easy to reach places (the "set" part of 5S).  As the tools were removed for use, you could see an outline of the tool painted in the box . Upon returning the tool, the mechanic could easily see where to put the tool  - much like placing a puzzle piece into a puzzle. This was especially valuable when many tools were being used at one time.  There was also a label describing the tool to ensure the correct tool was in its proper place. Regardless of the tool size the system was used and allowed a much more efficient operation. This is especially valuable because in building an aircraft you can't have unaccounted tools which could be left inside an airplane being assembled.

(Photo courtesy of leanblitzconsulting.com)

It didn't stop there. After each shift (and when required) the mechanics would literally "sweep" the floor and"sort" their work area of unwanted materials.  This became a regular expectation of the mechanics and helped to ensure the success of the "sustain" element of 5S.  I don't know how much the 5S system saved the factory.  But I did notice how  organized and efficient it became thanks to the mechanics would committed themselves to 5S.