KAIZEN MANAGEMENT: 5S and Gemba Organization
What is 5S?
5S is a Lean Kaizen philosophy that promotes a disciplined approach to problem solving within an organization through a systematic process of waste identification and elimination, standardization and organization of work processes. It includes, but is not limited to house-keeping so as to set the ground for further improvement of the gemba.
Caution: Do not use 5S as a standalone system
5S is a part of a set of tools that are used in the lean transformation. Just like any other tool, it has its place and should only be used at the right time for the right purpose.
Management preparation for a 5S Program
5S activities are a starting point for any kaizen program because of the following reasons:
- The spectacular gains that are achieved during the exercise help to get buy-in from the general workforce.
- Training of the critical mass of workers to drive the kaizen initiative can be done within a short time
- Team cohesion is achieved when workers are involved in any joint activity.
As a manager, it is important that you carefully select and prepare your team well for the 5S program before you start. This is because a lot of time and effort will go into the project and it can end up being a waste if proper preparation is not done. There are several steps that must be taken when starting a 5S program:
- Management decision
- Getting buy-in from staff (with the help of union reps)
- Team selection
- Training
Management decision to do 5S
The has to be a clear and deliberate decision by the top management to apply the 5S philosophy to the improvement of the work place and empowerment of the workers. Without the support of the decision makers, the likelihood of failure is very high. The initiative started by line managers are not any good if the company policy does not encourage it.
Staff buy-in
The program must be sold to the general workforce for it to get any kind of support. In unionised companies, the shop steward should be given a clear picture of what the program is all about and the intended result. Workers must be made to understand that the program will result in a better working environment for them. If for any reason they think that it will burden them more than their present jobs, they are likely to either sabotage your effort or passively resist.
Team selection
The team you select will determine whether you will achieve success or failure. You should only pick team member who will add value to your efforts and not joy riders.