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 

Champion 

Leader – Standardization 

Leader – Training 

Leader – Auditing and Assessments Leader – Rewards and Recognitions 

Leader – Events and Publicity Leader – Facility Management/Resources 

5S Coordinator

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