Guide to 6S Lean Management: The Fundamental Principles for Manufacturing Success

Unlock manufacturing excellence with our Guide to 6S Lean Management! Learn the core principles for optimal success in your industry.

Last Updated on January 30, 2024 by Ossian Muscad

You’ve probably heard about 5S Lean Manufacturing, but you may not be familiar with the 6S methodology. It basically follows the 5S lean manufacturing but added a sixth component: Safety. 6S aims to promote and sustain high productivity and safety levels throughout the workplace. It helps organizations promote an efficient working environment and establish a sustainable safety culture. 

If you’re already following the 5S lean manufacturing, upgrading it to 6S will make it even more effective and efficient at promoting workplace productivity and safety. Here’s a guide to 6S lean management and the fundamental principles for manufacturing success:

 

What is the 6S Lean Manufacturing System?

The 6S Lean Manufacturing System is a philosophy that hones in on creating an orderly and productive environment while minimizing waste and optimizing safety. Each “S” stands for a Japanese term: Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), Shitsuke (Sustain), and the additional Safety. The system is designed to improve efficiency by organizing the workspace in such a way that any tool, document, or piece of equipment can be accessed without unnecessary delay.

Moreover, this system encourages a continuous cycle of review and improvement that promotes operational excellence and ensures that the work environment is safe for all employees. Through 6S lean practices, businesses can achieve significant improvements in productivity and safety, leading to higher-quality products and more satisfied customers.

 

The 6 Components and Their Importance

Incorporating the 6S lean management system redefines efficiency by emphasizing order, cleanliness, and safety within the production process. This comprehensive approach empowers employees to contribute to a continually improving work environment. By consistently applying the six principles, companies can minimize waste, optimize productivity, and maintain a culture of safety.

Sort (Seiri)

The sort process is about eliminating unnecessary items from the work area to ensure a clutter-free and efficient workspace. This step involves evaluating tools, materials, and information, keeping only what is essential to the tasks, and disposing of or storing away the rest. This principle sets the foundation for a more organized and productive work environment.

Set in order (Seiton)

‘Set in order’ emphasizes the need for an organized workspace where everything has a designated place. By arranging and labeling tools and materials so they are easy to find and put away, employees can significantly reduce the time spent searching for items. It also contributes to a smoother workflow and lessens the chances of disruptions or accidents.

Shine (Seiso)

Shine focuses on maintaining a clean and orderly work environment. Regular cleaning and inspection are key, as they ensure that the workplace is hygienic and pleasant and allow for the early detection of potential issues, such as equipment malfunctions. A shining workplace also indicates a company that values its workers and operational efficiency.

Standardize (Seiketsu)

Standardization ensures that the best practices identified through the first three S’s are consistently applied. By creating uniform procedures and schedules for sorting, setting in order, and shining, the process becomes habitual and integrated into the daily work routine. This helps maintain the discipline needed to keep the workspace organized and efficient.

Sustain (Shitsuke)

Sustain is perhaps the most challenging step; it’s about maintaining and reviewing the standards over time. This requires continuous training, communication, and reinforcement to ensure that the practices of 6S are embedded into the company’s culture. Sustain is the key to continuous improvement and securing the long-term benefits of the 6S lean process.

Safety

The additional ‘S’ for Safety is critical as it integrates health and safety into the existing framework of 5S. This involves assessing and mitigating risks, promoting safe practices, and ensuring that the improvements in organization and cleanliness contribute to a safer work environment. Safety is the overriding principle that ensures the well-being of employees is always the top priority.

 

Why Include Safety?

Safety is a focal point in every workplace, and it should be given top priority. By including Safety in the 6S system, organizations can ensure that their workers are protected from potential hazards. Having a safe and clean working environment helps with the following:

  • Create a positive impact on quality and productivity;
  • Encourage a healthy and stress-free atmosphere where workers feel safe and secure and
  • Make it easy to recognize potential safety hazards and install effective safety controls.

 

Adding Safety helps provide twice the emphasis on safety issues, especially for industries that involve high-risk jobs like food manufacturing and construction. In addition, the extra attention given can help prevent hazardous items or conditions that can lead to accidents. Furthermore, the inclusion of Safety in the 6S system can help organizations to: 

  • Be wiser on expending resources such as energy and materials. 
  • Avoid productivity losses from occupational health hazards and injuries by providing a clean and accident-free work environment and 
  • Meet or exceed environmental performance and reduce waste at the same time.

 

How and Why Manufacturing Use 6S Lean

Manufacturers use the 6S Lean system as a structured program to systematically achieve total organization, cleanliness, and standardization in the workplace. The 6S methodology helps uncover inefficiencies, reduce errors, and streamline processes in a way that promotes sustainable operational excellence.

The adoption of this system is driven by the competitive need to produce high-quality products quickly and cost-effectively. The rationale behind using 6S in manufacturing is multifaceted:

Efficiency and Waste Reduction

6S Lean targets the elimination of waste—any activity that consumes resources but creates no value. By organizing the work environment (Sort, Set in Order), ensuring regular maintenance (Shine), devising standard procedures (Standardize), and enforcing adherence (Sustain), manufacturers can reduce the time and resources wasted on non-value-adding activities.

Safety Enhancement

Safety has a direct impact on production. A safer work environment leads to fewer accidents, which translates to less downtime and lower costs associated with worker injury. Safety integrated within the 6S framework goes beyond compliance—it becomes a daily operational practice that actively prevents hazards.

Quality Improvement

Organized and standardized environments tend to produce fewer defects. When workers have access to properly stored and maintained tools and when they follow standardized procedures, the likelihood of mistakes declines. This results in a higher quality product that meets customer satisfaction and reduces costly rework.

Employee Morale and Engagement

6S Lean involves everyone on the manufacturing floor, fostering an inclusive culture focused on continuous improvement. Engaged employees are more likely to take ownership of their workspace and processes, leading to higher job satisfaction and productivity.

Cost Savings

By minimizing waste and optimizing processes, 6S leads to cost savings. Lower waste means reduced material costs, while increased efficiency can reduce labor costs. Safety and quality improvements also eliminate costs associated with accidents and defects.

Sustainment of Competitive Advantage

In a market where consumers demand quick and agile responses to their needs, a manufacturing firm must be prepared to adapt. 6S Lean ensures that the organization is always ready to meet customer demands with agility and without compromising cost or quality.

Overall, 6S Lean is not just about cleaning up and organization; it’s about setting up a manufacturing system that is efficient, safe, and responsive to changes in demand—ultimately leading to a stronger, more competitive position in the marketplace.

 

Requirements of 6S Lean Manufacturing

Implementing a successful 6S Lean program within a manufacturing environment requires a robust foundational understanding and structured preparation. Key to this methodology is a fusion of rigorous organization and safety consciousness that facilitates operational excellence and a deeply ingrained culture of continuous improvement. The requirements to launch and sustain a 6S Lean Manufacturing initiative are expansive, necessitating commitment and resources from every level of the organization.

  • Thorough Understanding of 5S: Team members should be fully trained on the principles of Sort, Set in Order, Shine, Standardize, and Sustain to ensure the foundational practices are executed properly and consistently.
  • System for Hazard Identification and Reporting: A formal mechanism should be in place to identify, report, and act on potential safety hazards, ensuring the safety aspect of 6S is proactively managed and continuously improved.
  • Safety Awareness Training Relevant to Your Industry: Tailored training programs that address the industry’s specific safety challenges and regulations are vital to empower employees to work safely within the 6S framework.
  • 5S Toolbox Talks with Your Workers: Regularly scheduled discussions, or ‘toolbox talks,’ should be conducted to reinforce 5S concepts among workers, encouraging participation and feedback for ongoing refinement.
  • Approval from Upper Management: Secure commitment and active participation from leaders, as their support is crucial for providing the necessary resources and championing the cultural shift towards 6S within the organization.
  • Dedicated Resources and Support: Allocate adequate resources, such as designated personnel, time, and financial investment, to support the 6S activities and ensure their sustained application and effectiveness.

 

Different Ways to Complete ‘Safety’

The ‘Safety’ in 6S Lean Manufacturing encompasses a comprehensive approach to identifying and mitigating risks in the workplace. This strategic element ensures that safety is integrated into every aspect of operational processes, reinforcing the importance of a harm-free work environment. To effectively implement the ‘Safety’ aspect, the following initiatives are essential:

  • Awareness of Different Workplace Hazards: It is crucial to recognize and understand the various hazards that may be present in a manufacturing setting, ranging from physical dangers to chemical and ergonomic risks, to develop appropriate safety measures.
  • Risk Assessment: Conducting regular and thorough risk assessments helps pinpoint potential sources of harm, thereby allowing for the prioritization and control of risks through elimination, substitution, or administrative controls.
  • Job Safety Analysis (JSA): This systematic process involves breaking down a job into its component tasks and evaluating each for potential hazards to discover the most effective methods to perform each task safely.
  • Wear Appropriate PPE (Personal Protective Equipment): Providing and enforcing appropriate PPE, such as safety glasses, helmets, gloves, and protective footwear, is essential in safeguarding workers against injuries.
  • Training: Implementing comprehensive training programs ensures workers are knowledgeable about operational best practices, safety procedures, and proper use of equipment and PPE within the 6S framework.
  • Toolbox Meetings: These short, regular meetings provide a platform for discussing safety issues, reinforcing safety knowledge, and fostering an open dialogue between workers and management regarding safety concerns and suggestions.
  • Kaizen: Kaizen, or continuous improvement in the realm of safety, involves the ongoing evaluation and enhancement of safety protocols to prevent accidents and create an increasingly safe work environment.

 

Frequently Asked Questions (FAQs)

Q1: Is 6S officially a part of Lean Manufacturing?

Yes, 6S is considered an integral part of Lean Manufacturing. It was developed in Japan as one of the core principles of Toyota’s production system and has since been adopted by many other organizations. In addition, 6S complements the 5S methodology, widely recognized as a fundamental Lean tool.

Q2: What’s the difference between 5S and 6S?

The key distinction between 5S and 6S Lean lies in integrating Safety—a crucial component that complements and enhances the original 5S methodology. While 5S focuses on streamlining operations through organization and cleanliness to improve efficiency and eliminate waste, 6S builds upon this by incorporating a proactive emphasis on safety. This conscientious approach ensures that as operational environments become more efficient, they also become safer places to work, emphasizing that safety and productivity go hand-in-hand in achieving excellence in Lean Manufacturing.

Q3: Who is responsible for maintaining the 6S Lean program?

While everyone in the organization plays a role in the success of 6S Lean, there should be an appointed individual or team responsible for leading and coordinating the program. This includes maintaining momentum, conducting training programs, implementing new initiatives, and ensuring continuous improvement of the 6S process within the organization. However, it should be noted that company leaders are ultimately accountable for supporting and promoting 6S Lean as a core value.

Q4: Is it necessary to implement all six aspects of 6S?

While implementing all six aspects of 6S Lean is ideal, organizations can prioritize the areas that best align with their specific operational needs and goals. However, it should be noted that omitting any aspect may result in a less effective implementation of 6S and could potentially affect its overall success. Thus, careful consideration should be given to each aspect to ensure a well-rounded and comprehensive 6S Lean program.

Q5: Can 6S be used in other industries besides manufacturing?

Yes, while 6S was initially developed for the manufacturing industry, it can also be applied to various other industries such as healthcare, education, and office environments. The principles of organization, cleanliness, and safety are universally applicable and can bring significant benefits to any workplace. 6S can be customized and tailored to fit the specific needs of different industries, making it a versatile tool for improving efficiency, safety, and overall performance. Additionally, incorporating 6S Lean principles in non-manufacturing settings helps foster a culture of continuous improvement.

Q6: How often should you perform 6S audits?

Regular and frequent audits are crucial in maintaining the effectiveness of 6S Lean. The frequency of audits can vary depending on the organization, but it is recommended to conduct them at least once a month. Regular audits help identify areas that require improvement or additional attention and allow for prompt actions to be taken to maintain the standards set by 6S Lean. Moreover, audits also serve to keep the entire team involved and accountable for maintaining 6S principles in their workspaces.

 

Streamline 6S Lean Audits with DATAMYTE

DATAMYTE is a quality management platform with low-code capabilities. Our Digital Clipboard, in particular, is a low-code workflow automation software that features a workflow, checklist, and smart form builder. This tool lets you create custom checklists for 6S Lean audits and streamline the process.

DATAMYTE also lets you conduct layered process audits, a high-frequency evaluation of critical process steps. This audit focuses on areas with the highest failure risk or non-compliance. Conducting LPA with DATAMYTE lets you effectively identify and correct potential defects before they become major quality issues.

With DATAMYTE, you have an all-in-one solution for quality management, including 6S Lean audits, LPAs, and more. Our platform allows for real-time data collection, analytics, and reporting to help you track progress and identify areas for improvement in your 6S program. Book a demo now to learn more.

 

Conclusion

The adoption and rigorous application of 6S Lean principles can profoundly transform any workspace, fostering a culture of efficiency, safety, and continual refinement. Whether in manufacturing or other fields, 6S Lean offers a structured framework that organizations can employ to minimize waste, optimize productivity, and maintain a safe, orderly environment. By committing to this comprehensive approach, businesses can achieve not only immediate operational improvements but also lay a foundation for sustainable long-term success.

 

 

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