5S in the Process Industry

Vincent W. Howell

Corning Inc.

IIE / Process Industries Division

The philosophy of 5S is built around five terms

Sort (Seiri)

Deciding really what is needed to get the job done efficiently and effectively.

If it is essential for the job, it is tagged, and if it is not, it should be discarded.

Set in Order (Seiton)

Everything that is needed to do the job should be placed for easy access.

Every thing used, every tool, every SOP, the MSDS manual - everything used for the job must have a home where it can always be found when its needed.

Knowing where to look is the first step in the beginning of a standardized process

Shine (Seiso)

Keep the work area, process equipment, and everything used to make the product for the customer clean.

Standardize (Seiketsu)

A standardized process for maintaining the system.

Defining the standards by which personnel must measure and maintain 'cleanliness'.

Sustain (Shitsuke)

Making the 5S philosophy a way of life so that the organization can maintain the gains that have been achieved

SHITSUKE “focuses on defining a new status quo and standard of work place.”(4)

LESSONS LEARNED

5S can also be a jump start to other improvement

5S can build employee empowerment

5S Aligns Well with Environmental Control

5S Can Supports Staff Morale and Productivity

Some Final Thoughts

Process industry has success stories based on 5S implementation

5S is a good starting point

References / Extra Reading1. “5S – Visual Workplace,” http://www.tpslean.com/5s.htm2. “The five Ss: Number 4: Seiketsu (standardization),” Journal of the Institute for

Quality Assurance, http://syque.com/quality_tools/tools/Tools47.htm3. “The 5 'S' Process: Seiri, Seiton, Seiso, Seiketsu, Shitsuke ,”

http://www.siliconfareast.com/5S2.htm4. Skaggs, Todd, “Essential in Lean Manufacturing is The 5-S Philosophy,”

http://www.tpmonline.com/articles_on_total_productive_maintenance/leanmfg/5sphilosophy.htm

5. Steve Wichelecki, Steve, “Making It in Medical,” Quality Magazine, December 30, 2008, http://www.qualitymag.com/Articles/Cover_Story/BNP_GUID_9-5-2006_A_10000000000000494922

6. “Alza: Kaizen, 5-S Drive Development of Combination Product,” http://www.pharmamanufacturing.com/articles/2005/248.html

7. “Lean & Environmental Case Study: Columbia Paint & Coatings,” http://www.ecy.wa.gov/pubs/0704032.pdf

8. “Crystalmaker continues to move onwards and upwards,” http://www.allbusiness.com/nonmetallic-mineral/glass-glass-manufacturing/545686-1.html