How do you avoid common mistakes when applying the 5S method?

When considering implementing 5S, remember ... 1) It can be implemented in service organizations and be just as effective and impactful as manufacturing 2) It should really be considering as part of a larger continuous improvement program versus a 5S program deployment. Matt Rebeiro - Challenging the Status Quo #process #5s #lss #LeanSixSigma

Lack of commitment is often though of as lack of commitment by the team to the 5S process. A common more basic problem is lack of definition for the specific goals that the 5S event is supporting. Example: The Shipping area currently averages 10 shipments per shift. A goal of the 5S event is to improve the work area so that 12 shipments per shift is possible. Testing the before and after performance that the 5S event supports provides motivation to complete and maintain the 5S process. It also provides objective evidence that an event has made the progress desired or whether additional work is needed immediately.

From my experience a significant mistake is failing to incorporate a 5S practice in some shape of standard work (procedure, workstation instruction sheets, checklist, etc.). This leads to the exercise been performed only once, which defeats its purpose and shows inconsistency in continuous improvement behavior.

A necessary prerequisite for 5S is understanding your process. That can only be done if the true process experts are involved - the people doing the work. A major pitfall in lean implementation is having the engineers or managers tell the technicians what they need

When giving your team the freedom to try new ideas and experiment with different approaches you are encouraging creativity and innovation. Don’t forget to celebrate successes and learn from failures.

It is critical not to "set it and forget it", be sure to have champions who can advocate support and assign individuals who are responsible for revisiting each of the standards and procedures with access to the data that inform decision making.

It is important to emphasize the impact that 5S have on the KPIs. 5S is a systematic way, the foundation for continuous process improvement, zero defects, and cost reduction. A few methods can help establish a discipline to sustain 5S. For example, a standardized organizational radar chart, periodic audits, keeping stakeholders informed, and monitoring for continuous improvements.