Lean Manufacturing – Beyond 5s

LEAN MANUFACTURING – BEYOND 5S - 5S – Sort; Set in Order; Shine; Standardize: Sustain

Often we come across the statement ‘we have implemented lean’, only to find that the company is only practicing 5S in the manufacturing areas.

Agreed, the 5S is the initial and a very important step in the continuous improvement through lean implementation, but it is by no means the end.

In statistical terminology, we should consider whether a parameter meets the conditions of being ‘necessary and sufficient’.

5S provides a neat, clean and safe look to the workplace and improves the moral of the employees. If properly used, 5S gives a great base for inventory control, standardized work procedures, visual controls etc.

5S is ‘necessary’ for lean implementation, but is not ‘sufficient’.

So why are some companies content with 5S? What do we want to achieve through lean implementation?

An important objective is to be competitive so that the products (whether goods or services) are delivered to the customer in the shortest possible lead time. Due to globalization of trade, the competition is increasing in every field and the organizations with established and sustainable methods of process cost control become most competitive. Lean helps achieve shorter lead times, which in turn means more production within a given time or same production within a shorter time. Reduction in lead times improves competitiveness. Lean also helps achieve business stability, product consistency and profitability.

So, does implementing 5S alone help achieve the above goals or is there more?

Prashant Tipnis
Technolean Consultancy Services
Canada
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