Everything You Need to Know About 5S Lean

What is 5S system?

5S system is a five-step methodology for organizing workplaces by eliminating waste, improving flow, and reducing the number of processes where possible. The 5s methodology applies five core principles:

• Seiri (sort) - Keep what you need, while removing anything unnecessary.

• Seiton (set in order) - Keep things organized by labeling and assigning each item its own place.

• Seiso (shine) - Keep your workplace clean, while making it safe to work in.

• Seiketsu (standardize) - Keep operations and teams consistent by following standard procedures.

• Shitsuke (sustain) - Keep a culture of improvement by maintaining progress from the first four steps.

History of 5S

5S Lean was developed by Hiroyuki Hirano in post-war Japan, where it was famously utilized by Toyota. Originally designed for the manufacturing industry, the methodology helps improve efficiency in disorganized production lines. It also serves as a tool to combat the 8 wastes of lean manufacturing: defects, overproduction, waiting, underutilized talent, transportation, inventory, motion, and extra processing.

Today, major companies across industries such as HP, Boeing, Harley-Davidson, Nike, and Ford integrate 5S practices into their workflows. The beauty of 5S is its versatility: it can be applied anywhere, from complex fields to everyday spaces at home. Some 5S examples include arranging tools on vehicle assembly lines and keeping a home-office workspace clutter-free, making it easier to stay focused.

Importance of 5S Lean

The 5S Principles

5S is a launching pad for success in the global economy when done right. Applying the five principles of Sort, Set in Order, Shine, Standardize, and Sustain in the workplace can lead to more efficient and effective ways of getting the job done.

For example, business processes can flow more efficiently when employees constantly strive to clean and set their workspace in order. Organizations can begin to maximize the benefits of the 5S principles when they recognize the need to be proactive in reducing waste in any form, may it be wasteful movement, waiting time, or a step in the process.

Benefits of 5S

Although several successful companies that apply 5S are in manufacturing, 5S Lean is versatile enough to benefit any type of operation, regardless of its size and industry. Here are some general business benefits of implementing 5S in the workplace:

Waste Reduction

As evident in the name itself, 5S Lean aims to “trim the fat” from business operations so the relevant processes and components that remain can operate at maximum capacity. More specifically, it aims to eliminate the 7 types of waste: overproduction, transportation, inventory, motion, waiting, overprocessing, and defects.

Improved Productivity

Through the successful reduction of waste, productivity is naturally improved. Purchasing only the necessary equipment, materials, and tools ensures that workers spend less time sorting and more time producing. Optimizing old processes for efficiency means you get more work done in less time.

A Safer Workplace

Another side-effect of a “lean” workplace is improved safety. Having a well-organized and clutter-free working space lowers the risk of accidents such as slips and trips, toppling or falling objects, and exposure to hazardous materials. For a closer look at building safety into the 5S routine, read our guide to 6s safety.

Training and Certification

While the exact curriculum for 5S training programs may vary, it is important that 5S training succeeds in helping your team understand each of the 5 principles for effective 5S implementation, no matter how many organizational changes are made along the way.

What does a 5S training program look like?

Training participants are typically tasked with completing both individual and team activities covering each of the 5 principles. 5S training is best conducted in the individual or team’s place of work, as this maximizes efficiency by going through training while practicing 5S in your workspace.

Where can I get 5S training and certification?

Like Mitti (by SafetyCulture)’s Training, several websites offer 5S training materials and certification. 5S training bundles may also include 5S webinars and 5S assessment templates that team leaders and other personnel in charge can use to evaluate the participants’ application of 5S principles in their workspace.

Top Industries That Use 5S Lean

While the 5S method initially gained popularity by improving manufacturing processes, companies outside the manufacturing industry discovered that the 5S methodology would be versatile in any type of workplace. Below are some of the top industries that benefit from the 5S methodology, with practical 5S examples in action.

Manufacturing

By integrating 5S principles into the renowned Toyota Production System (TPS), Sakichi Toyoda set the foundation for Toyota to become a global leader in producing high-quality motor vehicles to this day. 5S in manufacturing has since become the standard for companies striving to maximize their potential.

Medical

5S in hospitals and medical practices can be used to promote orderliness, ensure proper labeling of medicines and paraphernalia, remove expired drugs from shelves, and establish daily routines that improve overall patient safety.

Retail

Sorting and organization are key to the retail industry, which makes 5S in retail a perfect fit. It can be applied to stock management, making items easy to find, while regular cleaning keeps the store safe and orderly. Ongoing staff training ensures consistent quality across all branches.

Hospitality

Organization, order, cleanliness, and consistency—the qualities customers expect in a hospitality setting—can be achieved through the 5S methodology. Integrating 5S in hospitality businesses improves operational efficiency and overall customer satisfaction. For example, it can be applied by arranging food ingredients according to their labels or by standardizing housekeeping routines in hotel rooms.

Computers and Technology

Many technology companies use 5S to boost efficiency. For example, Hewlett-Packard’s Computer Systems Division applies 5S by sorting and labeling computer parts to speed up system building. In software, 5S helps by marking frequently used tools for quick access and standardizing practices to maintain consistent performance across teams.

Education

Schools, first and foremost, should create an environment that supports learning. Classrooms benefit from 5S by removing unnecessary items such as excess seats, tables, and materials, so that students stay focused. Students can also apply 5S at home by organizing their books and prioritizing schoolwork.

General Office Setting

5S in the workplace applies across industries, as nearly all businesses have operations centers handling functions behind the scenes. Cluttered desks and untidy work areas negatively impact productivity and can lead to wasted resources. By removing unnecessary items, 5S boosts efficiency and can even reduce operational costs.

Implementing 5S in other aspects of the workplace, such as product management, project planning, or quality control, among others, also helps ensure that the processes included in them are organized and set up for success.