What is the difference between 5S and 6S?

The main difference between 5S and 6S is the addition of Safety as the sixth S. While 5S focuses on Sort, Set in Order, Shine, Standardize and Sustain, the 6S method explicitly adds Safety to reduce risks, prevent accidents and protect employees. This makes 6S especially valuable for high-risk manufacturing environments such as food, chemicals or heavy equipment.

How does the 6S method improve safety on the shop floor?

The 6S method improves safety by embedding safety practices into every step of workplace organization. Sorting and setting in order remove unnecessary items and trip hazards, shining and regular cleaning help identify defects or spills, standardization ensures everyone follows the same safe procedures, and the Safety pillar formalizes risk assessments, protective equipment, training and compliance with safety regulations.

How do you implement the 6S method in a factory?

To implement the 6S method in a factory, start by gaining support from management and employees, then form a team to lead the initiative. Apply the six steps in a pilot area: Sort what is needed, Set in Order using labels and visual cues, Shine through regular cleaning and inspections, Standardize procedures and responsibilities, Sustain with training and audits, and integrate Safety by identifying hazards, defining protocols and reinforcing safe behaviors. Once the pilot is stable, roll out 6S to other areas.

What tools and technologies can support the 6S method?

The 6S method can be supported with digital tools such as 6S checklists and digital visual management boards. Digital checklists help structure audits, inspections and job assignments, while visual management platforms like fabriq centralize procedures, standard operating instructions and safety information. These tools make it easier to track 6S activities, engage employees and sustain a strong 6S safety culture over time.

What is the 6S Method in Lean Manufacturing?

Q: What is the 6S method in lean manufacturing?

The 6S method in lean manufacturing is an improvement framework that builds on the traditional 5S methodology by adding a strong focus on safety. The 6S method helps manufacturers reduce waste, organize the workplace, standardize best practices and create a safer, more efficient shop floor.

Q: What does the 6S method stand for?

In lean manufacturing, the 6S method stands for Sort, Set in Order, Shine, Standardize, Sustain and Safety. Together, these six steps create a structured approach for organizing the workplace, maintaining cleanliness, standardizing procedures, sustaining good habits and integrating safety into all activities.

Every manufacturing unit strives to maximize efficiency and productivity. That’s where the 6S method of lean manufacturing comes in.

Consider this as an upgrade to the 5S Methodology originally developed by Toyota in Japan during the mid 1900s. Today, the 6S approach is relevant across all manufacturing industries. It streamlines operations, cuts down on waste, and creates a safer work environment.

This article discusses how the 6S method helps minimize safety risks on the manufacturing floor and gives you a practical guide to implement 6S in your organization.

What Does the 6S Method Stand For in Lean Manufacturing?

The 6S method supports the core principles of lean manufacturing. 6S stands for Sort, Set in Order, Shine, Standardize, Sustain, and Safety. Together, they create a holistic framework for a safe, efficient work environment.

A Step-by-Step Breakdown of Each Component in the 6S Method

Sort

Sort refers to sorting through the tools and materials being used in the workplace to select only those that are essential. You must eliminate anything unnecessary or no longer in use. This keeps your workplace clean and easier to organize. It also cuts down on distractions and makes it easier for employees to focus on the task at hand.

Set in Order

The next step involves organizing the essential equipment, tools, and materials identified in the ‘Sorting phase’. The main idea here is to cut down on the number of movements required to pick the required item. Additionally, use visual cues like color-coded markers, labels, etc. to ‘set in order’ for easier organization.

Shine

Shine focuses on routine maintenance and cleaning to maintain a safe, hazard-free working environment. Establish a set of cleaning protocols and schedules for the workplace. This keeps dirt and debris from building up around tools and equipment and, in turn, reduces the risk of malfunctions. Inspecting equipment for any defects or issues that could turn into potential safety hazards.

Standardize

To adhere to the principle of standardization, establish consistent processes to maintain the effects of the three previous steps. Document the steps followed, establish guidelines, define employee responsibilities, implement standardized workflows, and conduct regular audits to foster a culture of continuous improvement.

Sustain

The fifth principle, Sustain, makes sure the practices of Sorting, Setting in Order, Shining, and Standardizing become ingrained as regular activities. Achieve this through consistent training, employee engagement, ongoing reinforcement, and winning employee commitment at multiple levels.

Safety

This final principle on this list focuses on implementing safety measures into the various functional aspects of the workplace. It may involve a variety of practices. Establish safety protocols and conduct risk audits to provide safety training, hazard identification, making protective equipment available, and complying with safety regulations. This not only prevents accidents and injuries but also improves overall employee well-being.

The Difference Between 5S and 6S

The key difference between the 5S and 6S methodologies is the addition of the Safety component. By making the workplace safer, the 6S approach helps boost operational efficiency, lowers risk, and improves employee satisfaction. It is especially important for high-risk industries connected with food manufacturing, chemicals, construction equipment, and so on.

Common Safety Risks on the Shop Floor and How the 6S Method Helps

A 2023 report by the International Labour Organization found that nearly 3 million workers suffer from fatal workplace-related accidents and diseases each year. This includes slips and falls, accidents caused by improper use of heavy machinery, fires and explosions, exposure to harmful substances, etc. While it may not be possible to avoid all accidents, implementing the 6S methods can help minimize them.

Every small step helps. For example, sorting through equipment helps you keep only what you need. Organizing it makes things easier to find. This reduces the risk of accidentally dropping something dangerous and also cuts down on trip hazards.

Similarly, regular safety audits for equipment reduce the risk of accidents. It could be something simple like making sure a loose nut on a ladder won’t cause the step to break while a person is standing on it. Standardizing protocols has a similar effect. It ensures all employees follow the same sequence of steps and don’t try something that could cause a safety issue.

How to Implement the 6S Method in Your Factory: A Practical Guide

Whether it’s apparel or automobile parts, you need to take a structured approach to implement the 6S Method in any factory. Similar to the process of applying 5S methods, this process starts by getting support from company management and employees.

It’s a good idea to put together a team to lead your company’s 6S implementation. Start small when making changes. Test the process with a pilot project. This helps you find challenges and improve your approach before expanding.

If your workplace has many hazardous risks, it is smart to focus on the 6th S, Safety, in your operations. First identify and evaluate potential hazards. Follow this with a training program to help employees understand their responsibilities and become familiarized with safety protocols. Lastly, install visual cues around the shop floor to make the 6S method easier to understand.

Tools & Technologies to Support 6S Safety Culture

Despite the benefits, not all organizations can successfully implement the 6S methods. This is often due to resistance to change, poor communication, and an absence of proper employee engagement. The good news is that you can overcome these challenges by adopting the right tools and technologies. The top two among them are:

6S Checklists

Having clear, measurable goals and Key Performance Indicators empowers organizations to track the progress of their 6S initiatives. Structure these into checklists for job assignments, audits, inspections, etc. These checklists serve as reinforcement cues and help sustain standardized operating procedures.

Digital Visual Management Boards

Digital visual management boards like fabriq can play an important role in making these checklists easier to access and manage. They also foster communication and encourage employee engagement at all levels. Digitization removes confusion by making sure everyone has the latest version of the SOPs and checklists.

Choosing the Smart Way to Integrate 6S Methods in Your Factory

A safer workplace is a more efficient and productive unit. That said, embracing the 6S Methodology is all about fostering a culture of continuous improvement. This is not a one-time exercise. You need to engage your entire workforce, empower them to identify opportunities for improvement, and regularly review the effectiveness of your procedures.

This is where digital tools like fabriq can make a big impact. It enables your team to work with real-time information, centralizes data management, encourages collaboration, and drives continuous improvement.

Curious how a digital platform like fabriq can support your 6S implementation? Reach out for a demo of fabriq and we will help you get started.

Written by:

Keara Brosnan – International Marketing Manager @ fabriq

Keara brings nearly a decade of experience in B2B SaaS marketing and communications. With a B.A. in Strategic Communications and a passion for storytelling, she helps manufacturers understand how digital tools can streamline their daily operations.