The 5S method is a mainstay of lean management, and is essential for any factory that is looking to optimize its processes and improve its working environment. This article guides you through the steps involved in implementing the 5S method, as well as the benefits of an effective audit.
We’ll also explore common challenges and how to overcome them, drawing on the experience of Famille Michaud Apiculteurs, who succeeded in turning those challenges into opportunities thanks to an innovative approach. So let’s find out how this proven method can revolutionize your factory!
What is 5S? How it works and where it comes from
The 5S method, which originated in Japan, is an organized system for creating and maintaining a clean, safe and efficient working environment. “5S” refers to five Japanese words:
- Seiri (sort)
- Seiton (set in order)
- Seiso (shine)
- Seiketsu (standardize)
- Shitsuke (sustain)
The method aims to eliminate waste and improve productivity by maintaining an orderly workplace, which makes it easier to detect anomalies immediately.
Benefits of the 5S method
Implementing the 5S method on the factory floor provides tangible, measurable benefits. It enables a significant reduction in production cycle times and avoids unnecessary stocks and rejects, which represent direct losses for the company.
Product quality is therefore improved, which has a positive impact on customer satisfaction. The method also makes operators’ day-to-day activity easier. As Famille Michaud Apiculteurs confirmed it to us, a tidy environment not only means you don’t have to waste time looking for your tools, it also means you can work in complete safety, avoiding workplace accidents and occupational illnesses.
Another important benefit of the 5S method that Famille Michaud Apiculteurs shared, is that they were in better shape for any unannounced audits, making a good impression on the auditors.
By optimizing the use of production resources such as machines and tools, the 5S method plays a crucial role in continuous improvement and the achievement of operational excellence. The method is fundamental for any factory that is seeking to maximize its efficiency and competitiveness in the marketplace.
Implementing the 5S method in a factory environment
Certain key steps must be carried out so as to make sure you prepare the ground before introducing the workspace optimization methodology in a factory.
- Get all the relevant teams together
- Take stock of the current situation
- List improvement requirements
- Set priorities
- Draw up a schedule of actions to be put in place
- Monitor project progress regularly
These steps help the company to prepare for a structured and efficient introduction of the 5S method, ensuring a smooth transition to more organized and productive working practices.
5S method challenges in a factory setting
Challenges when implementing the 5S method may include:
- Resistance to change on the part of employees
- The initial investment required in terms of time and resources
- The need for effective training and communication to ensure buy-in from everyone involved.
Based on our experience with Fabriq customers, we recommend paying change management the attention it requires in order to overcome these challenges: it will make a huge positive impact on your transition! Here are a few pointers:
- Involve staff right from the start
- Clearly demonstrate the benefits of the 5S method
- Celebrate successes, however small
- Continuously train staff in the 5S principles to make it easier for them to accept the new work practices
The key is transparent communication of the benefits and regular monitoring to ensure that good practices are sustained.
How to make 5S happen – Famille Michaud Apiculteurs’ experience
The transition to digital 6S auditing at Famille Michaud Apiculteurs, a leading packager of natural sweeteners, is a concrete example of the benefits of technological innovation in continuous improvement processes on the factory floor.
With a production site in the Pyrénées-Atlantiques region and around 260 employees, Famille Michaud Apiculteurs has been using Fabriq for a year. Previously, the company relied on Excel files with macros for its audits, a method which had a wealth of data but also several limitations:
- Lack of scalability: the Excel files were inflexible and unable to cope with rapid changes in the production environment.
- Printing: the documents had to be printed when audits were carried out, which is both tedious and environmentally unfriendly.
- Illegible reports: the audit results were detailed, but often difficult to interpret for those who were unfamiliar with the Excel macros.
Given these challenges, the introduction of Fabriq proved a decisive turning point:
- Audits via cell phone: the 6S audit can now be carried out directly in the field using a smartphone, which makes the process more agile as well as more interactive.
- Ticket creation directly via the app: for each detected anomaly or opportunity for improvement, you can instantly create a ticket, assign owners and define corrective actions.
- Real-time documentation: operators can take photos and add them to the corresponding tickets, enriching the audit database with visual evidence.
- Simplified tracking: post-audit action monitoring is made much easier, enabling better task allocation and real-time progress updates on corrections.
- Intuitive and fun to get to grips with: Fabriq’s user-friendly interface promotes quick uptake by the staff on the ground.
Want to find out more about the difference digitalizing the 5S method can make to your factory? Contact us !
