6S Lean: 5S + Safety
6S (otherwise known as 5S + Safety) is a system that aims to promote and sustain a high level of productivity and safety throughout a workspace. While adhering to the 5S principle of Sort, Set in order, Shine, Standardize, and Sustain, the 6S method adds the concept of Safety. 6 S lean not only helps organizations promote efficient working environments but also establishes a sustainable culture of safety.
The 6 Components and Their Importance
What are the components of the 6s lean methodology and what is their importance in the overall system? Let us walk through each of the 6 S.
- Sort (Seiri)
Sorting, the first step in the 6s methodology, aims to reduce clutter and make it easier for essential work items to be easily located for improved efficiency. Red tagging is often done to mark unnecessary items for immediate disposal, while yellow tagging can be applied for those items that can be temporarily kept off-site for future use. - Set in order (Seiton)
In this stage of the 6 S system, items, equipment, and work materials tagged as essential in the first stage should be placed in an organized manner in the most logical locations. The objective of Set in Order (or Straighten) is to establish a systematic way of storing and retrieving items, thus helping maximize accessibility and space. - Shine (Seiso)
After non-essential items have been removed and essential items have been organized, the next step is cleansing. The third stage of the 6s lean system, also known as Shine, includes activities, such as cleaning the workplace, maintaining its pleasant appearance, and using preventive steps to keep workspaces tidy and clean. The objective is to create an environment that prevents injuries and products from being stained due to uncleanliness. - Standardize (Seiketsu)
Standardize is the fourth 6s method stage that aims to establish a new workplace norm by identifying best practices and creating consistent procedures for the first three stages. It aims to help people have the same work routines in their processes and develop more efficient habits. This can be done by providing visual reminders, setting expectations of workers responsibility, and conducting routine inspections and regular site checks. - Sustain (Shitsuke)
This is the most challenging step of the 6S method as the goal is to ensure that standardized procedures are applied continually over a long period of time until it becomes second nature in day-to-day work. - Safety
Lastly, 6S lean features Safety as the final step added to the standard 5S methodology many have been used to. This essential step of 6 S focuses on identifying hazards and setting preventive controls to keep workers safe during work operations and ensure that the work environment meets required safety standards.
Why Include Safety?
We know that Safety is the topmost priority in every workplace. Having a safe and clean working environment helps:
- Create a positive impact on productivity and quality;
- encourage a stress-free and healthy atmosphere where workers can feel safe and secure; and
- make it easy to recognize potential hazards and install safety controls.
Some believe that Safety is already integral to the classic 5S methodology; why then should it be incorporated as a separate step?
One reason lean improvement professionals say is that adding Safety helps provide further focus on safety issues, especially for industries that involve high-risk jobs, such as construction and food manufacturing. The extra attention given can help ensure that no hazardous items or conditions are overlooked after going through the five stages of 6s lean.
Further, having Safety as part of the 6S system can help an organization to:
- Be more prudent on expending energy, materials, and other resources;
- Avoid productivity losses from injuries and occupational health hazards by providing clean and accident-free work areas; and
- Meet or exceed environmental performance and waste reduction goals
Create your own 6s Lean safety checklist
Which System is Better for Your Organization?
When deciding whether to implement 6s or 5s for your team or company, it is best to assess which one will best meet your needs.
In workplace settings that are significantly more hazardous, it makes more sense to take the extra step and choose 6 S. This helps establish Safety as a crucial focal point of the organization and that there are specific Safety KPIs to be taken into account to measure improvement efforts.
Meanwhile, in workplace environments where there are very few significant safety risks, the 6th S may be considered unnecessary. In fact, having a 6th S in otherwise very safe environments could be seen as wasteful. When following 6S it is necessary to take the time to evaluate how different activities will impact the safety of the facility.
Whether you will implement 5S or 6S, organizations must remember that safety shall always be a priority. It is just a matter of choosing the right lean management strategy that will help meet your needs will while also ensuring that employees remain efficient with their work.
What is 6S Lean Software?
6s lean software is a digital tool that helps you carry out and document 6s implementation.Using 6s lean software such as SafetyCulture (formerly iAuditor), you can expect to get the following, as long as you are consistent with following your 6s system:
- Increased efficiency
- Standardized operations
- Higher productivity
Discover SafetyCulture features for 6s lean.
Implement and Audit 6S in Your Workplace Using SafetyCulture
Make your workplace clean and safe! Do it the 6S way! Get started bydownloading these free 5S and 6S use cases on our SafetyCultureplatform.
SafetyCulture gives you the flexibility to power any inspection you require. Whether you’re on-site, underground, or across the globe, conduct site inspections all in one platform designed for the unique needs of the manufacturing industry.
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6S Lean Templates
6S Lean Safety Checklist
Browse our collection of ready-to-use 6S Checklists you can use for free!
FAQs About 6s Lean
Yes, the 6s or 6S methodology is a subset of the larger Lean approach to process improvement. As a quality management technique often utilized in workplace settings, 6s Lean helps identify and eliminate waste by focusing on organization and cleanliness to create a culture of continuous improvement.
The main difference between 5s and 6s lean is the addition of the concept of Safety when implementing the 5s methodology. This additional focus on safety allows organizations to proactively identify workplace hazards and operational risks that can otherwise negatively impact a business and its people, if not promptly recognized.
The origin of the 6S Lean methodology can be traced back to the principles of the Toyota Production System. TPS, which is also considered the foundation of Lean methodology, emphasizes the importance of eliminating waste and continuously improving processes from there.
The frequency of 6s Lean audits can vary based on each 6s element in order to identify and prioritize areas that need more improvement. For example, Shine activities can range from daily to weekly assessments, while actions relating to Sustain can be reviewed from weekly to monthly audits, or as frequently as needed. Basically, areas that require constant attention are audited more frequently compared to those that are already well-established.
Jona Tarlengco
