6S - Is it really worth all of the effort?

What is 6S? Well, to start off with this is a concept that has actually been adopted and used within different parts of the manufacturing organization. The application that we will be discussing will involve the manufacturing / production area of the plant.

Lets start off with what 6S stands for:

1 - Sort (Define what belongs in the workspace)
2 - Straighten (Organize the workspace, assign homes for each item)
3 - Shine (Keep the workspace clean, and items in their home)
4 - Standardize (Create a standard procedure throughout)
5 - Sustain (Follow the procedure - Management Driven)
6 - Safety (Implement Safety requirements and follow)


What really is the goal behind 6S? It's a methodology that enables the production space to be kept organized in a way that is standard. Everyone knows where things are, where they go, and it's obvious if things are missing or perhaps low in inventory.

The goal is to create a visual work space. Where an operator/manager can walk out into a particular area of the facility and instantly know whats going on around them through an organization method that is visually oriented. If done properly and well kept, the plant should look presentable with relation to a customer visit on short notice.

Pros of 6S:
--Clean appearance.
--Organized.
--Visual aids in place to communicate process to individual.
--Consistent look throughout the plant.
--Items are were they need to be and can be easily found.
--Helps to improve the companies appearance and brand during customer visits.


Cons of 6S:
--All employees must understand and buy into methodology.
--Management must also buy into methodology.
--The proper Management theology must be applied in order to sustain.
--Doesn't happen over night. Takes time to implement, train, and sustain.
--Requires a culture change for everyone at the company.

So, is 6S really worth it? I believe it is. It allows the operators who are performing the manufacturing operations to stay productive. They don't need to search for what they need. The items are easy to get. It helps to take away any confusion of how the process is laid out and suppose to work. Can make training new operators much easier and faster. Raw Materials also gain better location and placement which results in better process cycle times and more accurate inventory levels. And this is just the beginning...