Resistance to 5S Implementation

The Five Ss
Resistance to
5S Implementation
• What’s so great about Sort and Set in Order?
– The fact remains that 5S implementation is needed when
the factory is not neat and organized.
• Why clean when it just gets dirty again?
– Sometimes people accept dirtiness as an inevitable
condition in their workplace.
– They say that cleaning it up would do little good since it
would soon get dirty again.
– This logic doesn’t hold, however, when we look at the
negative impact of a dirty work place on the quality and
efficiency of the work
Resistance to
5S Implementation
• Sorting and Setting in Order will not boost output.
– Production workers assume their job is to make things, not
organize or clean things.
– This is an attitude that needs to change as workers learn
how important the Sort, Set in Order, and Shine activities
are to actually maximizing output.
• We already implemented Sort and Set in Order
– People some times think that rearranging things a little
and putting them into neat rows one time is all there is to
– However, such “orderliness” only scratches the surface.
Resistance to
5S Implementation
• We did 5S years ago
– This is heard most often from people who think the 5Ss is a
fad rather than a continuous activity.
– 5Ss is actually a basis for making all other improvements.
• We’re too busy for 5S activities
– 5Ss is one of the first things passed over when work gets
busy or production priorities become critical.
– Since 5S is fundamental to factory operations, putting it off
for too long a period can have negative consequences.
Resistance to
5S Implementation
• Why do we need to implement the 5Ss when
we are so successful today?
– It can be difficult to implement the 5Ss or any
improvement program at companies that are
currently profitable.
– If you tell workers that it is more efficient to keep
only one box of parts on hand at each operation,
they may respond by saying”Yes, but we’re doing
all right, and this is the way we’ve always done it.
Resistance to
5S Implementation
• These types of resistances are common in the
early stages of 5S implementation.
– If we ignore such resistance and plow ahead with
implementation, the result is likely to be nothing
more than superficial improvements.
– Instead, we need to address these concerns
• In order for the 5Ss to work, everyone needs
to truly understand just how necessary they
Benefits of
5S Implementation
• 5S should have many benefits for you. It will
– give you an opportunity to provide creative input
regarding how your workplace should be organized and
laid out and how your work should be done.
– make your workplace more pleasant to work in.
– make your job more satisfying.
– remove obstacles and frustrations in your work.
– help you know what you are expected to do, and when
and where you are expected to do it.
– make it easier to communicate with people you work
Benefits to
Your Company
Zero changeovers
Zero defects
Zero wastes
Zero delays
Zero injuries
Zero breakdowns
Zero complaints
Zero red ink
Benefit to
Your Company
• Zero changeovers bring product diversification.
– To remain competitive, companies must reduce
changeover times to zero, increase changeover
frequency, and become more adaptive to product
– The 5Ss help lower changeover time by reducing
material and tooling searching times and raising
overall operator efficiency.
Benefit to
Your Company
• Zero defects bring higher quality
– Defects result from many causes including
attaching the wrong part and using the wrong jig.
– Sort and Set in Order prevent these kinds of
– Further, keeping production equipment clean
reduces equipment-operation errors and enables
faster retooling.
– These and other effects of 5S implementation all
add up to fewer defects.
Benefit to
Your Company
• Zero waste brings lower costs
– In-process and warehouse inventories
– The use of excess amounts of space for storage
– Stand-by waste while waiting for equipment to
transport items
– Searching waste, when items are hard to find.
– Motion waste, in side-stepping poorly located
equipment and supplies
Benefits to
Your Company
• Zero delays bring reliable deliveries
– Factories that lack thorough 5S implementation tend to
produce defects no matter what they try to do to prevent
– Deadlines are missed due to wasted motion and too many
errors and defects while products are being reworked
• Zero injuries promotes safety
– Injuries can be expected when items are left in walkway,
when stock is piled high in storage areas, or when
equipment is covered with grime, cutting shavings, or oil.
Benefit to
Your Company
• Zero breakdowns bring better equipment
– When daily maintenance tasks are integrated with
daily cleaning tasks, operators notice problems
before they cause a breakdown.
• In this way, equipment is more consistently ready for
– Clean, well-maintained equipment breaks down
less frequently and is also easier to diagnose and
repair when breakdowns do occur.
Benefits to
Your Company
• Zero complaints bring greater confidence and trust
– Factories that are virtually free of defects and delays are
also free of customer complaints about product quality.
– Products from a neat and clean workshop
Are defect-free
Cost less to make
Arrive on time
Are safe to use
• Zero red ink brings corporate growth
– Companies cannot grow without the trust of customers.
– The 5Ss provides a strong base upon which to build
customer trust and loyalty.
To Be Competitive, Boldly
Go Where No One Has Gone Before!

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