The 5 pillars are defined as Sort, Set in Order, Shine, Standardize, and Sustain. The most important elements among these are “Sort” and “Set in Order” as the success of improvement activities depend on them.
The First Pillar: Sort
Sort can be defined as the systematic removal of unnecessary items from the workplace to streamline current production operations. Initially, eliminating items from the workspace may not be easy, as individuals often cling to components, anticipating their potential use in future orders. Consequently, inventory and equipment tend to amass, obstructing daily production activities and culminating in extensive waste throughout the factory. Implementing a “red-tag holding area” to assess an item’s necessity before disposal significantly mitigates the risk of discarding potentially essential items.
The Second Pillar: Set in Order
Set in Order involves organising essential items for ease of use and labelling them for quick identification and storage. It should always be implemented with the sorting process. After sorting through everything, only the necessary items should remain, ensuring a clutter-free and efficient workspace.
The Third Pillar: Shine
Shine comprises of activities such as sweeping floors, wiping machinery, and maintaining overall cleanliness in the factory. It plays a crucial role in ensuring the production of quality products in a manufacturing company. Additionally, Shine involves implementing measures to prevent the accumulation of dirt, dust, and debris in the workshop, thereby optimizing labor efficiency.
The Fourth Pillar: Standardize
Standardize differs from Sort, Set in Order, and Shine as it is not an activity in itself but rather the method employed to uphold the principles of these initial pillars. While Sort, Set in Order, and Shine involve actions, Standardize focuses on maintaining them consistently. Although Standardize is relevant to all three pillars, its strongest association lies with Shine. It is achieved by ensuring machines and their surroundings remain free from oil and dirt, reflecting the sustained practice of Shine over time.
The Fifth Pillar: Sustain
Sustain means cultivating a habitual commitment to maintaining proper procedures. The successful implementation of the first four pillars hinges on fostering an environment where employees consistently uphold 5S conditions. Such a workplace is poised to achieve high productivity and superior quality standards.
During the initial implementation of the five pillars, various forms of resistance are bound to emerge. These may include a lack of understanding regarding the significance of the five pillars, reluctance to engage in cleaning activities due to the inevitability of subsequent dirt accumulation, and the perception that organizing, ordering, and cleaning the workplace is incompatible with a busy work schedule. If left unaddressed, such resistance can undermine the company’s efforts in 5S implementation.
Benefits of 55 Implementation on a personal level include:
- a workplace that’s more pleasant to work in.
- job satisfaction by removing many obstacles and frustrations in work.
- help in understanding the expectations of what to do, when to do and where to do.
- make it easier to communicate with everyone we are working with.