5S Success Stories

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The 5S system transformed a plant of ~50 people from a cluttered, inefficient state to a facility that is "setting the standard for welding operations". With the active involvement of the owner and all employees, four truck-loads of unneeded "stuff" were removed from the premises to allow new flow arrangements, kanbans, andon lights, tools, and work areas to be set up for more efficient operations. Clean floors became the standard with easy access to raw materials and supplies. Welding utilization rose from <50% to 75-80%, Worker Comp losses dropped 97%, and customer returns dropped 15%.

Several teams in a large company with ~500 employees applied their 5S training to target six areas in their 60-year old facility. They uncovered much clutter, disorganization, house-keeping and safety concerns. One lab found several years supply of chemicals that kept being re-ordered because they could not put their hands on the supply that was there. The 5S system gave them permission to take control of their work areas and is expanding into other areas.

A 5S training session chartered teams to address three target areas in a facility of ~100 employees. Workplace organization and kanban supplies allowed one area to reduce lead time by 65%. The other two areas set up Kanbans to maintain supply and WIP inventories between defined minimums and maximums. Expansion of 5S to other areas is planned.

At a large production plant of ~250 employees, I knew that 5S training was being effective when a preventative maintenance mechanic stated that he didn't have to clean the equipment before working on it. Prior to 5S, he spent the first ½ hour of the PM just cleaning.