Lean Manufacturing

Read this chapter. It presents the lean 5S approach to workplace organization and safety. It also covers the Kaizen idea of continuous improvement. Kaizen seeks out and identifies waste, inconsistencies, and strain on people and machines. Reflect on your current or previous job. What types of waste occurred, and how would you apply the Kaizen philosophy?


After completing this unit, you should be able to:

    • Apply 5S in any Machine shop.
    • Describe Kaizen Concept.
    • Describe Implementing Lean Manufacturing.

Lean 5S:

"5S" is a method of workplace organization that consists of five words: Sort, Set in order, Shine, Standardize, and Sustain. All of these words begin with the letter S. These five components describe how to store items and maintain the new order. When making decisions, employees discuss standardization, which will make the work process clear among the workers. By doing this, each employee will feel ownership of the process.

Phase 0: Safety

It is often assumed that a properly executed 5S program will improve workplace safety, but this is false. Safety is not an option; it's a priority.

Phase 1: Sort

Review all items in the workplace, keeping only what is needed.

Phase 2: Straighten

Everything should have a place and be in place. Items should be divided and labeled. Everything should be arranged thoughtfully. Employees should not have to bend over repetitively. Place equipment near where it is used. This step is a part of why lean 5s is not considered "standardized cleanup".

Phase 3: Shine

Make sure that the workplace is clean and neat. By doing this, it will be easier to be aware of where things are and where they should be. After working, clean the workspace and return everything to its former position. Keeping the workplace clean should be integrated into the daily routine.

Phase 4: Standardize

Standardize work procedures and make them consistent. Every worker should be aware of what their responsibilities are when following the first three steps.

Phase 5: Sustain

Assess and maintain the standards. The aforementioned steps should become the new norm in operation. Do not gradually revert to the old ways. When taking part of the new procedure, think of ways to improve. Review the first four steps when new tools or output requirements are presented.

Source: LamNgeun Virasak, https://openoregon.pressbooks.pub/manufacturingprocesses45/chapter/chapter-7-lean-manufacturing/
Creative Commons License This work is licensed under a Creative Commons Attribution 4.0 License.