5s: A tool for excellence at a glance
“What is 5S?”, Not just a tool but has become a requirement for modern industries to stay in the competitive market now a day. As much as it helps to improve quality of a product, it also helps to create a flexible culture in an industry by improving communication in top management and front-line workers. This paper primarily focuses on five stepped processes involved in 5S: Seiri, Seiton, Seiso, Seiketsu, Shitsuke and different aspects of 5S such as necessity, implementation, impact, future research of 5S. This five-stepped process can help an organization in creating a visual workplace that helps to find out the areas of improvement. This continuous going process constantly keeps on making changes in industries that along with time seeks perfection. Because of having many benefits of 5S it is popular and widely accepted amongst the companies that focus on quality, cost and performance.
Keywords: Self-discipline, Culture, Safety, Cleanliness, Training, TPM.
5S is one of the revolutionary tools in lean that were used by Japanese companies at first and later were introduced to the world while maintenance was a major concerned issue in industries. The industries in other countries started using 5S when they found that results were remarkable, they adopted lean tools like 5S and made certain changes to it according to the requirements. Later, 5S was known as one of the most pivotal tools in lean manufacturing for making changes in productivity and quality. It is often considered as a foundation for applications of TPM, Kanban, JIT. These tools eventually lead to continuous improvement that helps to seek perfection. While 5S is known to bring out changes in organizational performance, operational performance and financial performance. 5S is well known popular tool in industries for some of its benefits. 5S lead to improve quality by reducing wastes like defects, waiting and overproduction.5S helps in creating a well-organized and structured workplace by removing unnecessary items that are not required during production. When the workplace is well organized and structured it reduces the time required for production in manufacturing. Working out 5S to get proper results requires a flexibility in top managements and frontline workers, when 5S is implemented in an organization it eventually acquires that flexibility. When performance is improved, loss of waiting is reduced because of prevention of losing of tools it implies to reduction in cost which is the most considered thing to increase profitability.
In this paper we have reviewed 35 different research papers with case studies in some of them. The case studies revealed many surveys in manufacturing, service and in health sector. In given themes in this paper we have tried to cover almost all the aspects of 5S.
- Review Protocol
3.1 Research question 1: How 5S is evolved under the influence of the Japanese Culture?
The origin of 5S methodology can be found in the Japan as the tool to improve the standard of living with the philosophy of the Shintoism, Buddhism and Confucianism. (28). The 5S concepts extensive use can be seen from the Second World War (De Mente,1994). First implemented by the Toyota Production Systems (TPS) was based on the 3S (Seiri, Seiton, Seiso) which then evolved to the 4S by the Taiichi Ohno. 5S was developed as the tool for maintenance derived from the concepts like periodic, predictive, corrective maintenance adopted from the USA. Boeing from USA first identify 5S as the world class tool for continuous improvement. (14) 5S is nothing but the innovative way to implement the total productive maintenance in its early stage of its development further integrated with the KAIZEN. To understand this concept, it is necessary to study the views of the Osada’s philosophical view towards 5S to improve life along with business and the tools/techniques approach of Hirano. In Osada’s view 5S can be used for improvement in every sector which helps to enrich the culture and society. His model for 5S is cyclic in nature where the seiri, seiton, seiso and seiketsu can be used in any random order or simultaneously which also helps in maintain discipline which is fifth “S” shitsuke. According to Osada for the successful implementation of the 5S the behavior of the employee’s needs to be disciplined. While another view of Hirano is based on the practices to be used in the organization. His focus was more on the first two Seiri and Seiton to have a Just In time production. His focus can be seen in the goals of the lean implementation as identifying waste is related to sorting the necessary and unnecessary things or events. Eliminating waste can relate to minimizing the unnecessary events and increase the productivity could be the keeping necessary items to the optimum level. Accordingly, Hirano the top management should be active to implement the 5S effectively and the model is linear with first two S being implemented simultaneously and next two in second stage. From these two-model’s today’s 5S is defined in the sequence Seiri-Sort, Seiton-Set in order, Seiso-shine, Seiketsu– standardize and Shitsuke– Sustain. From the comparison between the view of Japanese and Western organizations towards 5S we can say that western organizations are using it as a tool to improve workplace while Japanese view that as way to improve mindset of the people along with the improvement of the workplace.
3.2 Research question 2: What is the significance of implementation of 5S in an industry?
Organizations frequently battle to enhance efficiencies and think about how best to approach increasing the value while lessening waste. To create and assess the agenda review for the 5S rehearse in two assembling companies, to address current insufficiencies in the execution of 5S method in chose companies by saying that it has to offer recommendations to enhance 5S usage at the company. The motivation behind this paper to examine the effect of lean production practices on execution measures in machine tool industry. (12). 5S is used to determine the lean criteria that can have critical positive effect on execution, to see if vigorous 5S framework makes other lean instruments inadequate or not to comprehend the 5S in detail and to discover why now and then 5S works and some of the time not. 5S helps to encourage the presentation and advancement of other quality and nonstop change strategies and systems, to discover part of best administration responsibility in the usage of the same. Also the requirement of 5s is to think about unto what broaden 5S executed adequately and effectively, to get to the impact of 5S usage in enhancing workplace, to see whether there is any real distinction in execution of 5S in sub focus, to ponder the utilization of 5S strategy in western associations, to consider the devices for and arranges in fruitful execution of 5s in association, the point of this paper is to advance the 5‐S system and investigate the reasons why it has been generally utilized as a part of Japan as the initial move towards TQM in both the assembling and administrations and portrays the Japanese 5‐S practice, the rationale behind which is that association, tidiness, cleanliness, institutionalization and teach at the working environment are fundamental prerequisites for delivering high‐quality items and administrations, with almost no waste, while keeping up large amounts of efficiency. With the assistance of the 5S standards, a business can finish these objectives without spending a considerable measure of cash. 5S is a framework to diminish squander and enhance efficiency through keeping up an organized work environment and utilizing visual prompts to accomplish more predictable operational outcomes. Also, to outline normal 5S hones and give engaging rules to administrative practice on the premise of 5S standard, to investigate how supplies administration for lean creation resemble, to look at what changes should be done while provider is actualizing the 5S and finally to break down which 5S usage factors (Communication, Training, Reward and Recognition and Top Management Role for 5S) that will impact worker inspiration.
3.3 Research question 3: What Factors should be considered while implementing 5s in industry?
5s is the basic ground for any organization to move towards continuous improvement and achieve perfection. Hence implementation of 5S plays important role, there are various factors from shop floor worker to top management plays crucial role. We will discuss various factors regarding 5s implementation such as Top management commitment, Communication, 5S Audit, Top management Support, Training, Rewards and Recognition. Communication gap (18) between two employees or from top management to shop floor worker should be minimum as possible it will lead to unity at work and employee feels motivated and gives positive feedback to any project in organization. Top management commitment to achieve 5S is also one of the factor because they are the one who will give all required resources to implement 5S, so their seriousness in project gives positive energy in the 5S implementation. Employee involvement (6) is the next factor that should be taken in to account while considering 5S because employees are going to perform it daily to maintain 5S, so their involvement will give positive result of 5S very quickly. Behavioral change in all employee (Brainstorming) should be carried out because 5S should be strictly followed by every employee then all the advantages of 5S can be achieved very fast. Training and 5s related events (7) should be carried out with the 5S team and explain every s of 5S to team by leader it will change the viewing angle of employee and make it easier to implement 5S. Implementation of 5S in the supplier also very important over the overall quality of an equipment. Also, 5S is also important in healthcare sector it will improve the quality of service and attitude of staff towards the patient (26). 5S Auditing is also important it will keep track of all 5S activity to perform it on time and in correct method. So, while implementation of 5S all above factors should be taken into count to overcome all issue.
3.4 Research question 4: What is the effectiveness on performance of implementation of lean in industry?
5S is a pivotal tool that is used in industries to keep the workplace organized. When the workplace is organized, it automatically creates a major change in performance, quality and cost. Time required for the production reduces. As 5S also helps in keeping the shop floor clean, it prevents the waiting losses like losing of tool or missing tool. These small changes occur after the implementation of 5S and they bring major change on performance and productivity. An application of 5S brings out drastic change in energy requirement of the production process. Reduction of energy expenditure implies to the reduction of cost. When 5S is used in an industry to obtain continuous improvement and higher productivity it is obvious that 5S strongly supports the objectives of industry. With all the dynamic changes occurring in industries now a day, the industries have become competitive and the only way to keep on lead with other competitive firms is to maintain quality and cost. There are three types of performance improvements in an organization that are organizational performance, operational performance and financial performance; the organizational performance measures the effectiveness and efficiency, the operational performance is related to measuring performance against standards and financial performance is the use of money and its efficiency. When performance is considered after implementation of 5S, it is found that there are many factors that get improved which lead to the improvement in performance such as cost, quality and cost. There are certain links that should be considered while we expect improvement in performance after implementation of 5S; some of the examples of these links are significant link between top management and employees, link between effectiveness and practices and link in objectives of an organization and practices. While 5S is used for suppliers to obtain performance improvement, it is important to consider that it is necessary to keep the proper linkage between supply chain and 5S for best results.
3.5 Research question 5: What is the future scope of 5S? How can it be improved?
It is normal that the input of the present investigation will give a genuine situation on the issues looked by assembling firms with respect to workers’ inspiration in executing 5S System. Likewise, scientists can utilize the investigation’s discoveries as their future reference on workers’ inspiration. Although there are a few restrictions, it is trusted that the initial step taken in concentrate the components impacting representatives’ inspiration in actualizing 5S System is huge for encourage support. The most critical future work should be done in territories that are identified with absence of correspondence, hole between the best administration and shop floor representatives and furthermore the absence of preparing and cognizance of this movement among the staff. Along these lines, the full advantages of the 5S can’t be knowledgeable about the business division until the point when every one of the hindrances related with usage of the system are recognized, completely comprehended and tended to. Consistent appraisal in the two organizations is one key driver to changing the way of life of the association. This evaluation ought to be focused on the advance and change in view of all contribution from this investigation. Having a separation will be valuable when endeavoring to finish a usage of the 5S activity appropriate for a medium scale organization. As far as building up the bundle utilizing the product, having the subtle elements of the assessors, a remark page, and examination of the information are great applications for the following exploration.
- Collecting the literature body
The following literature body have been made by categorizing 35 different research papers (Some of them with case studies) on the basis on yearly activity, citations, surveys, methodology and sectors.
|1999||13, 23, 25||3|
|2009||4 ,10, 19||3|
|2011||27, 28, 31||3|
|2012||12, 22, 26||3|
|2014||11 ,21, 33, 35||4|
|2015||1 ,15, 16,20||4|
Table 4.1: Papers published per year
The table 4.1 represents the year, number of papers published and the sum all papers in the end (Appendix A). An Internet organization called Quality Assurance Solutions uncovers that the historical backdrop of 5S backpedals way back to the sixteenth Century and Venice shipbuilders. With an end goal to streamline the get together process, laborers utilized quality process creation to fabricate sends in hours rather than days or weeks. From that point, it was Sakichi Toyoda and his son named Kiichiro and Toyota build Taiichi Ohno who went to build up the 5S procedure or what they called the Total Production System of TPS after World War II. In this table above, we have enlisted the most recent transformation of 5s system which has reached to a pinnacle of apex, so we have started by the years from 1996 to 2016 as the most recent one.
4.2: percentage from industry sectors
The pie chart (4.2) above shows the percentage of use of 5S in various sectors of like healthcare, service and manufacturing. As we can see from the above that service sector uses the maximum use of 5S which is an approach for work environment associations; it drives work environment proficiency and efficiency change. In view of a basic arrangement of standards, it not just recognizes squanders in the work environment yet additionally makes a domain wherein groups get engaged with enhancements. Also, we can see that the manufacturing sector is not far behind with 42.86% of this sector have been implementing 5S since 1996 whereas the heath sector stands behind but the of use of 5S in recent years it looks like that the health sector will be able to walk hand in hand with the other counterparts.
Table 4.3: Research Methodology
The graph 4.3 shows the different ways of research methodology which we have used which are as follows peer reviewed article, research paper, case study, technical paper, journal among which Journal article normally short papers on subjects and are the maximum number which are twenty, followed by research paper which is an extended article that shows an assessment which are five, and case study’s which is for a particular instance of something used and technical.
Table 4.4: Study Methods
The graph 4.4 shows the different methods used in this summary namely including primary, secondary and both. The primary classification includes questionnaire, interviews and research data and have cumulated to about eleven and secondary classification includes annual reports, journals, textbooks which sum up to eleven as well and then the combination of both have come up to thirteen.
5.1 Theme 1: Defining the 5s
From the study of the thirty-five journals we can identify the three main sectors where the 5S is being implemented effectively and those sectors are the Manufacturing, Service (Non-profit organizations can be added for example education) and Healthcare. From the literature review we found that most of the (25 out of 35 papers) authors find it important to define and explain the meaning and function of each S in the 5S. In this paper we are trying to summarize all the definitions in terms of what we understood about the 5s. Each S has its own meaning and importance which we are discussing below:
5.1.1 Seiri: (Sorting)
The first step in implementing the 5S is sorting the unwanted items and necessary items. This term can be related to the identifying the waste from the goal of the lean. If we take the example of the manufacturing company (24) in sorting step unneeded equipment’s, parts and inventories were identified and removed with the help of red tagging. These red tagged items are needing to eliminate with the sale, recycling or any other means. The factors like material availability, defective goods, operating conditions, relative information with workplace can also be used in rating the level of seiri. (32)
5.1.2 Seiton: (Set in Order)
After the elimination of unwanted items arranging the necessary items with accordance of ease of use to increase the efficiency of the work. This includes the arrangement of tools and equipment’s to avoid the waste of waiting due to loss of parts and mistake proofing. For this the employees need to brainstorm together on the opportunities to improve workplace concepts based on the experience from the Sort stage. While order is to be set the material arrangement for easy access, tool arrangement for minimum lead time and equipment arrangement for smooth flow of product. This should lead to the increase in efficiency of the production.
5.1.3 Seiso: (Shine)
Shine step consist of the cleaning of the workplace to keep it safe and comfortable to work. In this stage each person of the team needs to take the responsibility of the workplace they are working on. It is also necessary to consider the ergonomics of workstation to provide proper light and air, also it is necessary to avoid waste of motion which will keep worker energetic and help in minimizing the errors during the operations. (24). The factors like cleaning of the machine, process path cleaning is supposed to be analyzed to maintain the safe and accident free environment consistently.
5.1.4 Seiketsu: (standardize)
This step involves the formulating the best practices into the standard form which could be followed by the individual to maintain or raise the efficiency of the workplace. This can be done with the simple document called standard operating procedures (SOP’s) containing instructions of steps and procedures to be followed. These procedures are supposed to be safe, elaborative about the tools and material required for the efficient production of the product. This will help workers to be efficient, mistake proof and ultimately achieving the goals of lean manufacturing by the all means. Currently the visualization techniques like color coding, slogans, indicating lights are being used to make the workplace more pleasant leading to boost the efficiency. (18)
5.1.5 Shitsuke: (Sustain)
Once the standardization of the process is done over the period of the implementation 5S. Even If we assume that we are at the maximum efficiency it is tough to maintain it over the long period. For this the individual working should be disciplined to do thing repeatedly as they are supposed to be done. This be the Deming’s PDCA cycle as the element of the Kaizen event to attain the ultimate efficiency. Self-discipline is the key trait to be rooted in the organization for this training should be given to the workers and reward system should be implemented to motivate the employees.
For the success of the 5S the commitment and communication between the top management and employees is must. Getting top management committed, promotion campaign with the available resources, training, keeping records and evaluating the progress are key steps to be followed to succeed.
5.2 Theme 2: Need and necessity of 5S
The 5S use in manufacturing plants (15 papers on manufacturing related to 5s) uses the logical variables involving basic highlights of the firm, condition, HR and innovation and quality administration. The execution measures allude to changes in profitability, quality, worker fulfillment, lead time and new item outline. (7)
Sort is way of organizing things in a systematic way in the work region and keeping just basic things everything else is either put away offsite or disposed of. Things to be disposed of are put in a “nearby red label zone” for evacuation. Red labels help distinguish unused things the objective is to dispose of insignificant things from the work environment. Things are “red labeled” and put away in a neighborhood red tag range for a timeframe, ordinarily five days. If not recovered by the work gathering, things are then moved to one of the organization’s focal red label regions. Here everybody can filter through the things to check whether there is anything they require. Set in order incorporates building up highlights in the work environment that influence it to clear that there’s a place for everything and that give visual signs to enable individuals to succeed. It concentrates on the requirement for organizing all the items and equipment in a request that increases ideal work process. In set in order all the items to be placed are labelled properly assigned a designated location where they are to be placed. The team members work collectively to achieve the required result of getting everything organized right to get their things done. Having assigned areas for all things in the work zone empowers team members to take control over their operations. Team representatives will have the capacity to quickly check whether things are strange and if more materials, supplies, or instruments need to be requested. Now in case of shine, 5s concentrates on having visual request, association, cleanliness and institutionalization. 5s is an orderly approach which complies with all deliberate methodologies which end with clear accomplishments if performed is an ordinarily utilized Lean instrument that focus on making a sorted-out workplace, however the impacts of 5S on safety environment are not too contemplated, the reason for this paper is to decide the effect of a 5S occasion on safety environment and the other manufacturing companies, service and hospital industries. In case of standardize roles and responsibilities must be properly understood and the steps should be taken in order to keep the same standard and which can be achieved by maintaining a certain sequence like color coding, checklists, tables, flowcharts and various diagrams and enhances importance of 5S. The management team need to focus on the activity with a specific end goal to give direction, and in addition to give general support to the group. Team members consequently should grasp 5S standards and practices keeping in mind the end goal to help execute these progressions into their work zone. Identifying boundaries and advantages to lean assembling, decide a chain of importance, assuming any, for the usage of lean apparatuses, to research and clear up the routes in which 5S has been comprehended and actualized by Japanese and western Businesses. Here it is it a mandatory to ensure all partners that means the stake holders know about the new standard that is they must me given the additional data and information for the necessary changes made. Finally, in sustain management inspecting procedure ought to be tried to guarantee that the team members comprehend that keeping up the level of working environment association is a best need. Management reviews should concentrate on guaranteeing that the schedules and timetables indicated in Standardize are in effect legitimately kept up. The review likewise gives a fantastic chance to making inquiries and giving proposals that fortify further upgrades.
We have also learned from the paper that discoveries uncover that the acquaintance of 5S relates to better execution as far as efficiency and quality. We consider this conclusion, generally acknowledged in the scholastic and expert writing, to be exceptionally significant. Top management should consider that endeavoring to keep request and neatness in the plant in a thorough and precise way can prompt a change in quality and efficiency and, as an outcome, in intensity. The execution measures drive attention to upgrades in efficiency, quality, representative fulfillment, lead time and new item outline.
5.3 Theme 3: Implementation of 5S in Industry
As we discussed about the need of 5S in above section its implementation is important, we will discuss in paper regarding various factors on which we have to work on. During the implementation phase communication is a stage on which every industry (small scale or big scale) must work upon. Communication (7) between top management to shop floor worker should be always quick and friendly, it will always bidirectional not unidirectional. It will always encourage the employee to perform on the higher level. After the communication behavioral change in an organization is must, change in your habit it will improve work result. Cleaning and safety which is part of 5S should be the priority to every employee. It will change the viewing angle towards the work of every employee and continuous improvement can be easily carried out. 5S event and training (6) should be conducted periodically to understand other employee about importance of 5s and how can we achieve it. In the literature review conducted on Mexican manufacturing organization in that survey is conducted on the top management commitment (1) to implement 5S in that quality manager, top management and shop floor workers are included, in that survey top management commitment directly related to implementation 5S practice in their organizational strategic planning, management should track, measure, and evaluate the 5S implementation. 5S implementation in organization always improve productivity of your production line as well as it will change the working culture of your organization. Due to 5S workplace become more visible hence improvement areas can be easily find out and perfection in your work area can be easily achieved.
Due to improvement in the visible workplace it will increase the safety and make your workplace more pleasant. Due to 5S storage area, large inventory problems are also resolved. Implementation of 5S in supplier is also mandatory requirement for most of bigger firm while selecting the supplier, so supplier end 5S will leads to overall product quality. Now a days 5S is important in healthcare as well it creates change in the process and vision of staff to cure a patient. 5S leads to increase in quality of service Attitude and behavior of employee in healthcare (26). 5S is necessity or foundation for other lean tools like TPM, Kanban, JIT so their implementation is very vital in organization to achieve good business results. For this promotional campaign or event should be carried out in an organization to explain importance of 5S to achieve good business result. This kaizen event or 5S event explain every employee, to change their vision about their work.
New culture will motivate the people to work and unidentified problem can be seen very easily, and lean goal can be achieved. Another factor to consider while implementing 5S is Audit worksheet or 5S process chart this will help supervisor to keep track and evaluate the 5S activity and help to understand on which s of 5S should have to work upon. These 5S audit work sheet will also help to analyze the work carried out and issues can be easily removed with the help of this tool. In the Display board or Poster will help to promote the 5S event in organization. With the help of this we can give information to various employees about its importance. Rewards and recognitions in the team building is very important, in 5S activity rewards and recognition will give motivation to another employee to work on it. If you are trying to implement 5S in organization, you must fight against negative things as well that is resistance to change (31), it is strong resistance to change by employee because according to human behavior no one likes changes in their environment and those resistance can prevent implementation of 5S and its benefits. So, leaders and managers should avoid resistance to change in their team and every team member should welcome new and wild ideas and improve their work cell to next level of perfection.
5.4 Theme 4: Impact of 5S: Improvements and Results
As well known, 5S is a tool for making remarkable changes in shop floor of a manufacturing industry or service industry regarding cleanliness, organized structure, performance and cost. As mentioned in the previous themes, 5S is a tool that can be brought in application when certain changes are to be made in a process or industry. 5S helps in bringing flow into algorithm and that leads to many changes or improvements. The main improvements that can be made through 5S are reducing the amount of inventory, eliminating the excess inventory, removal of things that are not necessary in process, giving a right place to everything according to the priority or use, keeping the workplace clean and the last one is making changes that lead to continuous improvement. This theme mainly focuses on some of the case studies presented in research papers and the changes that company could bring that helped in improvement of quality and reduction of cost. First case study presented was of a Polish company of a machine industry. In this company, when 5S was introduced to workers they were asked different questions about controls. After continuous implementation of 5S in production process of this company, they found that they could reduce the cost, they were making better usage of working area and they had always faced a problem with losing tools which was prevented (29). A standalone company named ‘Hubbard’ explained the 5S as a foundation for continuous improvement. In a research paper called ‘5S methodology implementation in the laboratories of an industrial engineering university school’ presented by four authors in April 2015. Results of different laboratories are presented after the application of 5S (24). The first laboratory was sheet metal forming and cutting. They found that there is major reduction in accidents after implementation of 5S. Second laboratory was integrated manufacturing systems. They found that implementation of 5S leads to increase in safety. Third laboratory was welding laboratory that found reduction in time for setting up things, cleaning and training. Fourth laboratory was metrology laboratory. After implementing 5S they found that there is direct impact on operations and anomalies identification. In a paper called ‘Implementing 5S to promote safety and housekeeping’ two case studies are presented. First one is of Boeing Co. and another one is of Cooke Brothers Ltd (8). In the first one 5S was a tool used for productivity and quality initiatives. At first the employee had reacted like it was not their work, their work was to complete and control process. After the smooth communication between workers and top management everyone could see the results. According to Boeing Co. safety and housekeeping can be achieved with proper implementation of 5S. While in Cooke Brothers Ltd. A small manufacturing firm with 98 employees implemented 5S by providing in-house training to their workers. They successfully implemented 5S mainly in smaller operations. They found that 5S is an important tool to obtain improvement in housekeeping, safety, health and environmental performance. In a research paper called ‘5S for suppliers’ by a journal Quality Progress by American society for quality control stated that 5S is not just a pivotal tool to obtain improvement and quality in manufacturing (9). Even suppliers can also use 5S and eventually it was found that the relation between purchasing personal and general management was improved. The program ‘Visual Workplace’ can help much to suppliers in operations. According to author Bullington Kimball E the linkage of supply chain and 5S can be brought in use to obtain best results while applying 5S to suppliers. Thus, there are many case studies presented in research papers and above mentioned were the important examples of industries that brought 5S in use and received expected results. Thus, 5S is a pivotal tool to obtain many improvements that lead to improvement in quality and reduction in cost.
- Theme 5: Future Research
The concept of 5S has been implemented in industries as well as other fields but there’s is still scope for improvement. Future work will talk about the philosophy usage master techniques in different situations, also the adjustment of the 5S procedure with safety as the new 6S. To guarantee that all faculty engaged with the 5S execution are touchy to wellbeing in the working environment, there is the likelihood to expand the extent of the 5S system to one more security. A spotless work environment, efficient and with visual signs of dangers, is a protected working environment. The loads up and marks establishment enables laborers to know constantly what the potential dangers are. 6s Is designed according to the 5s procedure change framework intended to diminish squander and enhance efficiency in the work environment by creating and keep up association and organization, using visual signs to accomplish more reliable operational outcomes, reducing defects so that accidents occur less. Environment health and safety (EHS) should be included in 5S it makes defects more improbable, so less vitality and material are squandered. Maintain a strategic distance from efficiency misfortunes from wounds and word related wellbeing risks by giving clean and mischance free work regions. Meet or surpass your organization’s natural and waste diminishment objectives Counting security endeavors in the general business targets can help accomplish a more elevated amount of cooperation. Joining lean assembling activities with wellbeing work force and aptitude yield security comes about that are very much lined up with whatever is left of the association. Little research has been directed into the distinctive courses in which 5S has been deciphered and actualized in the UK and US contrasted and its unique significance. Examination of the site pages of organizations in Japan, the UK and the US recommends critical contrasts in the path in which the 5S idea has been connected. In Japan, 5S has been held onto and actualized as a reasoning or lifestyle. In the UK and US, 5S has been actualized as a procedure or device. In administration practices received by a portion of the best producers situated in the south of Japan, and their connection to 5S. examines demonstrates that 5S standards are available in Japanese organizations’ exercises and administration rehearses, and that they encourage the effective usage of change procedures in organizations. Japanese esteems, for example, shared regard, steadfastness, collaboration and expert improvement are regularly found as the premise of administrative strategies in organizations. In view of those generally shared esteems, it is less demanding to empower worker cooperation and duty in those organizations. Nonetheless, these standards can be received by organizations in different nations using the standards and practices saw in this exploration: advancing 5S bunch exercises, profession advancement through preparing projects, and regard and look after individuals’ solace and wellbeing, and building up non-debatable and clear principles. These standards ought to be connected through specialist acknowledgment and preparing from one viewpoint, and through enduring, quiet and predictable authority on the other. The present examinations reasons that there are huge and positive connections amongst interchanges and preparing with representatives’ inspiration in executing 5S System while negative relationship for the best administration bolster. Other than that, in view of the discoveries, reward and acknowledgment have no critical association with the worker’s inspiration in executing 5S System. As a conclusion, it is trusted that the consequences of the present investigations have contributed profitable data to the future scientists. Other than that, it is trust that organizations particularly in assembling can pick up advantage and make utilization of the outcomes to enhance approaches and programs with respect to 5S System.
With the above study we can summarize 5S as tool to improve the efficiency of organization concurrent with the increase in the quality, safety, standard of living and mindset of the individuals involved into organizations. Being under the influence of the holistic culture of Japan, Western organizations also engaging in the same view intentionally or otherwise. From the study we can outline some of the key traits for implementation for the 5S. Commitment of top management for the success of 5S can lead to the better involvement of the employees and this can happen only if the employees are trained to be disciplined in order to work on the standards set for success consistently. For this results of the 5S audit should be communicated between the managers and workers which will lead to built teamwork. The behavioral change will help to establish 5s culture in organization. Also, as we have established the importance and benefits of 5S in above chapters, 5S is the tool for to acquire improvements in performance, cost, quality, flow and safety. Organizational, operational and financial performance needs to be assessed but what management is looking is the financial benefit can be obtained with change made under 5S implementation. So, its team’s responsibility to standardize workplace accordingly. 5S helps to identify waste, eliminating waste leading to reduction in production time and increase in profit which is ultimate goal of lean manufacturing.
In this era where technology plays an important role, the competition challenges are ever so increasing and 5S will not be able to solve the extreme challenges because the big organizations claim that without 5S there cannot be any more improvements and changes. There is a lack of management support because of the many reasons preventing them from getting the additional finance and time required for the implementation of the 5S. Employees are usually hesitant to change and don’t accept the changes so easily because of which training, and education is needed to provided and which results in loss of finance and time. On the other hand, the employees don’t report the problems as they are reluctant to share their opinions and views to the upper management. The employees are ignorant about the usage of 5S so constant training is needed.
6.2 Future research
As we already know that there are five important steps in 5S, now with involvement of the environment safety regulations getting more strict day by day the environment health and safety(EHS) has been introduced and is its early stages and will take time to get implemented and will need more development and research.
We are thankful to our instructor Mr. Adam Lynch and teaching assistant Mr. Ravi Patel for their invaluable guidance for this systematic research paper.
This research paper is not funded by any profit – nonprofit organization.
Appendix A: Literature Body
- Moriones and Pintado (2010)
- Hidge and Ross (2010)
- Michalska & Szewieczek (2007)
- Kobayashi & Fisher (2008)
- Gapp & Fisher (2008)
- Eswaramoorthi & Kathiresan (2010)
- Chapman (2005)
- Ab Rahman (2010)
- Balle & Reginer (2007)
- Taylor & Francis (2009)
- Jacaa & Vilessa (2014)
- Pujol (2012)
- Ho (1999)
- Qureshi (2013)
- Cicmil & Fung (2005)
- Patwa & Patel (2015)
- Ho (1997)
- Ho & Cicmil (1996)
- Khamil & Rahman (2009)
- Jimeneza , Romero & Espinosa (2015)
- Bullington (2003)
- Ananthanarayanan (2006)
- Kanamori & Castro (2013)
- Ikuma (2013)
- Hallgreen & Olhager (2009)
- Ikumaa & Nahmens (2012)
- Al-Aomar (2011)
- Hojjati & Mohammed (2011)
- Ho & Cicmil (2016)
- Gabow, Albert & Kaufman (2008)
- Juhari , Abidin & Omar (2011)
- John (2001)
- Chang & Chen (2014)
- Randhawa & Ahuja (2016)
- Gupta & Jain (2014)
- Ablanedo-Rosas, J. H., Alidaee, B., Moreno, J. C., & Urbina, J. (2010). Quality improvement supported by the 5S, an empirical case study of Mexican organisations. International Journal of Production Research, 48(23), 7063-7087.
- Ab Rahman, M. N., Khamis, N. K., Zain, R. M., Deros, B. M., & Mahmood, W. H. W. (2010). Implementation of 5S practices in the manufacturing companies: A case study. American Journal of Applied Sciences, 7(8), 1182-1189.
- Al-Aomar, R. A. (2011). Applying 5S LEAN Technology: An infrastructure for continuous process improvement. World Academy of Science, Engineering and Technology, 59, 2014-2019.
- Ananthanarayanan, K. R. M. (2006, December). Application of 5S management system in NDE laboratory. In National seminar on non-destructive evaluation.
- Aremu, M., & Ayanda, M. (2008). Impact assessment of business process reengineering on organisational performance. European Journal of Social Sciences, 7(1).
- Ballé, M., & Régnier, A. (2007). Lean as a learning system in a hospital ward. Leadership in health services, 20(1), 33-41.
- Bayo-Moriones, A., Bello-Pintado, A., & Merino-Díaz de Cerio, J. (2010). 5S use in manufacturing plants: contextual factors and impact on operating performance. International Journal of Quality & Reliability Management, 27(2), 217-230.
- Becker, J. E. (2001). Implementing 5S: To promote safety & housekeeping. Professional Safety, 46(8), 29.
- Bullington, K. E. (2003). 5S for suppliers. Quality progress, 36(1), 56.
- Chang, Y. C., & Chen, C. Y. (2014). Prioritisation on 5S activities for a semiconductor wafer fabrication: an empirical study. International Journal of Quality & Reliability Management, 31(4), 380-394.
- Chapman, C. D. (2005). Clean house with lean 5S. Quality progress, 38(6), 27-32.
- Eswaramoorthi, M., Kathiresan, G. R., Prasad, P. S. S., & Mohanram, P. V. (2011). A survey on lean practices in Indian machine tool industries. The International Journal of Advanced Manufacturing Technology, 52(9-12), 1091-1101.
- Gabow, P. A., Albert, R., Kaufman, L., Wilson, M., & Eisert, S. (2008). Picture of health: Denver health uses 5S to deliver quality, safety, efficiency. Industrial Engineer, 40(2), 44-49.
- Gapp, R., Fisher, R., & Kobayashi, K. (2008). Implementing 5S within a Japanese context: an integrated management system. Management Decision, 46(4), 565-579.
- Hallgren, M., & Olhager, J. (2009). Lean and agile manufacturing: external and internal drivers and performance outcomes. International Journal of Operations & Production Management, 29(10), 976-999.
- Hegde, H. G., Mahesh, N. S., & Doss, K. (2009). Overall Equipment Effectiveness Improvement by TPM and 5S Techniques in a CNC Machine Shop. SaSTech, 8, 25-32.
- Hojjati, H., & Mohammad, S. (2011). IMPLEMENTING 5S SYSTEM IN PERSIA NOOR FACTORY. International Journal of Industrial Engineering, 18(8).
- Ho, S. K. (1997). Workplace learning: the 5-S way. Journal of Workplace Learning, 9(6), 185-191.
- Ho, S. K., & Cicmil, S. (1996). Japanese 5-S practice. The TQM magazine, 8(1), 45-53.
- Ho, S. K. (1999). 5-S practice: the first step towards total quality management. Total Quality Management, 10(3), 345-356.
- Ho, S. K., Cicmil, S., & Fung, C. K. (1995). The Japanese 5-S practice and TQM training. Training for Quality, 3(4), 19-24.
- Ikuma, L. H., & Nahmens, I. (2014). Making safety an integral part of 5S in healthcare. Work, 47(2), 243-251.
- Jaca, C., Viles, E., Paipa-Galeano, L., Santos, J., & Mateo, R. (2014). Learning 5S principles from Japanese best practitioners: case studies of five manufacturing companies. International Journal of Production Research, 52(15), 4574-4586.
- Jiménez, M., Romero, L., Domínguez, M., & del Mar Espinosa, M. (2015). 5S methodology implementation in the laboratories of an industrial engineering university school. Safety science, 78, 163-172.
- Juhari, N. H. B., Abidin, N., & Omar, M. W. (2011). Factors influencing employees’ motivation in implementing 5s system. Elixir International Journal, 39, 4836-4847.
- Kanamori, S., Sow, S., Castro, M. C., Matsuno, R., Tsuru, A., & Jimba, M. (2015). Implementation of 5S management method for lean healthcare at a health center in Senegal: a qualitative study of staff perception. Global health action, 8(1), 27256.
- Khamis, N., Abrahman, M. N., Jamaludin, K. R., Ismail, A. R., Ghani, J. A., & Zulkifli, R. (2009, July). Development of 5S practice checklist for manufacturing industry. In Proceedings of the World Congress on Engineering (Vol. 1, No. 3, pp. 1-5).
- Kobayashi, K., Fisher, R., & Gapp, R. (2008). Business improvement strategy or useful tool? Analysis of the application of the 5S concept in Japan, the UK and the US. Total Quality Management, 19(3), 245-262.
- Michalska, J., & Szewieczek, D. (2007). The 5S methodology as a tool for improving the organization. Journal of Achievements in Materials and Manufacturing Engineering, 24(2), 211-214.
- Randhawa, J. S., Randhawa, J. S., Ahuja, I. S., & Ahuja, I. S. (2017). Evaluating impact of 5S implementation on business performance. International Journal of Productivity and Performance Management, 66(7), 948-978.
- Gupta, S., & Jain, S. K. (2015). An application of 5S concept to organize the workplace at a scientific instruments manufacturing company. International Journal of Lean Six Sigma, 6(1), 73-88.
- Rojasra, P. M., & Qureshi, M. N. (2013). Performance improvement through 5S in small scale industry: a case study. International Journal of Modern Engineering Research, 3(3), 1654-1660.
- Suárez-Barraza, M. F., & Ramis-Pujol, J. (2012). An exploratory study of 5S: a multiple case study of multinational organizations in Mexico. Asian Journal on Quality, 13(1), 77-99.
- Srinivasan, S., Ikuma, L. H., Shakouri, M., Nahmens, I., & Harvey, C. (2016). 5S impact on safety climate of manufacturing workers. Journal of Manufacturing Technology Management, 27(3), 364-378.
- Venkateswaran, S., Nahmens, I., & Ikuma, L. (2013). Improving healthcare warehouse operations through 5S. IIE Transactions on Healthcare Systems Engineering, 3(4), 240-253.
Cite This Work
To export a reference to this article please select a referencing stye below:
Related ServicesView all
Related ContentAll Tags
Content relating to: "Manufacturing"
Manufacturing describes the process of using raw materials to produce goods. Manufacturing involves workers making use of heavy machinery, tools, and other resources throughout the process.
Globalization Strategies: Ford vs Toyota
A comparison of the globalization strategies of Ford and Toyota including joint ventures, manufacturing and marketing....
Effects of Manufacturing Practices on the Delivery Time in a Supply Chain
Assessment of the effects of manufacturing practices on the delivery time in a supply chain Abstract. The literature suggests that nowadays companies use to evaluate the delivery time of their produc...
Thermoplastic Composites with High Mechanical Properties and a Low Processing Temperature
The main aim of the current project is to design thermoplastic composites with high mechanical properties and a low processing temperature that could be used in the construction, automotive and aircraft industries....
DMCA / Removal Request
If you are the original writer of this dissertation and no longer wish to have your work published on the UKDiss.com website then please: