The 5S methodology is a widely known tool of Japanese origin that is part of the foundations of lean manufacturing.
Learn more about this useful methodology, its benefits and how we live and breathe it daily at Nutec Bickley.
What 5S means for us
We have been employing this methodology for nine years, using it extensively not only in operational areas, but also in our offices, communal areas, warehouses and externally.
When new employees join the company, they take on board the 5S rules and regulations as part of their induction; we share with them how the methodology is embedded at Nutec Bickley and each of the five concepts involved, as follows:
Seiri (Sort)
Identify what items are not used in the workplace, and separate them out from those that are.
Seiton (Set in Order)
Useful articles should have a defined place and be labeled to facilitate their location.
Seiso (Clean)
Work stations are cleaned after tasks are completed, in addition to maintaining their functionality and keeping them looking good at all times.
Seiketsu (Standardize)
Establish standards that help prevent clutter.
Shitsuke (Sustain)
Self-discipline, aimed at maintaining order and cleanliness, thereby increasing productivity.
How do we implement each of the five concepts at Nutec Bickley?
In 2011, with the support of a consulting company, we had a thorough education in the methodology and then planned a comprehensive implementation across our administrative and operational processes.
1.All operational and administrative areas were divided into sections, to be addressed individually.
2.We selected a group of facilitators to be put in charge of the project.
3.Each facilitator became responsible for implementing the standard and being the spokesperson for the methodology in their area.
4.Work commenced on one 5S concept per month, including the use of company broadcasts and making improvements through the facilitators.
5.Upon reaching the fourth S – Standardization – the participation of the directors was once again key, since with their support we created the ‘Manual of order and cleanliness’ covering all areas in which 5S is relevant to Nutec Bickley.
6. We designed a monthly audit plan with well-defined roles, in which the entire organization participated, from director to operator level.
Measuring the results in our organization
The role of directors as auditors is a way of leading by example. In the implementation process we achieved nearly 2,000 improvements in the various areas of the organization, with each of the departments making their own improvements on a weekly basis.
Over time, the system matured, with the decision being made to include some industrial safety requirements in the weekly audits. Thanks to this, we have been able to detect administrative flaws and areas of opportunity to reinforce policies.
Major benefits from 5S implementation
Over time we have gained a large number of benefits, such as:
• Boosted productivity by doing more with less
• Development of employee engagement and improved worker safety
• Reduction in response and transport times; having the necessary tools to hand
• Guaranteed optimal operation of equipment, by monitoring its condition during each weekly audit
• Delivery of world-class products
• Electronic debugging, through the digital review of computers, files, emails, etc.
We constantly work on optimizing our processes, which is why we currently have a lean, productive program in which we all participate.
We also carry out follow-ups through frequent audits (weekly, bi-weekly or monthly, depending on the area) to assess the level of compliance, with a goal of 90% in 5S methodology.
At Nutec Bickley we are committed to guaranteeing world-class quality in our products, seeking in all our processes to play close attention to even the smallest of details; so in our operations we promote a culture of best practice, with order and cleanliness as fundamental principles.
