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International Journal of Research in Industrial Engineering (Dec 2021)

Analyzing the Impact of 5S implementation in the manufacturing department: a case study

• Tasnim Ahmed Tahasin,
• Himadri Sen Gupta,
• Noshin Tasnim Tuli

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5S is a systematic approach that helps to organize a workplace for increasing efficiency and reduce wasting of productivity by providing an organized safe environment. The objective of this paper is to emphasize the implementation of 5S principles for the workplace by reflecting a tooling problem of a manufacturing unit. This article examines the challenges experienced in the implementation of 5S methodology to optimize labor and safety in a manufacturing department by showing the gap of productivity caused while not having 5S methodology in workplaces. The time consumption analysis of 5S implementation through shadow boarding demonstrates workers who have been able to perform work more efficiently along with a significant reduction of searching time of tools. The results showed that 5S along with the shadow boarding technique creates improvement in efficiency, workspace, equipment search time, working environment and safety. Consequently, this shadow boarding technique would strongly support the objectives of multinational companies to achieve continuous improvement and higher performance.

• 5s lean tool
• lean manufacturing
• shadow boarding foam
• visual inspection

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Implementation of 5S Methodology : Case Transval Group

Immonen, niko (2016).

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Warehouse Improvement with Lean 5S-A Case Study of Ulstein Verft AS

2010, Journal of Business Strategy

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5S Implementation to Minimize Waste in Bread Production Process (Case Study: Madani Bakery)

• Conference paper
• Open Access
• First Online: 26 April 2023
• Cite this conference paper

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• Nilda Tri Putri   ORCID: orcid.org/0000-0003-3514-5675 13 ,
• Dicky Fatrias   ORCID: orcid.org/0000-0001-8039-3497 13 &
• Santa Rosa Roberta Simbolon 13  

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Included in the following conference series:

• Global Conference on Sustainable Manufacturing

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This paper aimed to implement the 5S concept at Madani Bakery by using PDCA (Plan, Do, Check, and Action) to reduce waste. The problems found in the bread industry have not implemented 5S so that there is waste during production activities. The method that can be used to overcome these problems is to apply 5S and PDCA so that they can make continuous improvements. The initial data used is the result of observing the initial conditions before implementing 5S and then determining Plan, Do, Check, and Action (PDCA). Based on observations at Madani bakery, two types of waste were found, namely unnecessary motion and transportation. Madani Bakery has not yet fully implemented 5S, there is still dust, items are in random condition, and there are still unused items at the work station. 5S deployments are designed to improve workstations and reduce unnecessary waste movement and transportation. The limitation of this research is that the application of 5S is carried out according to the conditions of the production area at Madani Bakery. This research can be useful for Madani Bakery to create a comfortable work environment and reduce working time caused by waste during production activities. This research is expected to help Madani Bakery to implement 5S so that it becomes a work culture to reduce waste. Repairs to work stations at Madani Bakery can be used in other industries in implementing 5S and creating a work culture. Working time was cut to 784.34 min, and waste was cut to 11.773 min.

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1 introduction.

The economic success of a country can be seen from its level of economic growth which is indicated by the value of the Gross Regional Domestic Product (GDP). The processing industry in various fields in Agam Regency, West Sumatra based on data from the Central Statistics Agency (BPS) is in the eleventh position. One of the production areas of the food industry is bread. Bread consumption in Agam Regency, West Sumatra has increased based on data from the Indonesian Central Statistics Agency (BPS). The challenge faced by Madani Bakery is the growing development of the white and sweet bread industry in Agam, West Sumatra. There are similar businesses that produce bread with various flavors.

5S is a method used to make improvements with the aim of increasing system performance, increasing productivity, reducing the time required to add value, and improving products quality [ 2 ]. The benefits of implementing 5S are reducing the activity of looking for goods, reducing waste, reducing the possibility of work accidents, reducing costs downtime, and better space utilization. The implementation of 5S can be carried out by all employees regardless of their education so that they can be an organized workplace, create a clean work environment, increase safety, and be able to perform continuous improvement of work stations [ 1 ]. The PDCA or Deming Cycle method is a method used to make continuous improvement with future orientation, flexibility, and logic. There are four phases used in this method, namely planning, implementation, testing, and implementation. The PDCA cycle is carried out for corrective, temporary, and permanent repairs to eliminate the root cause and fix the problem [ 4 ]. A plan is a strategic plan for achieving the targeted results, do is carry out a plan or target, check is an inspection condition before and after repair, and action is taken to standardize or fix problems [ 6 ].

The 5S method according to Houa for creating a comfortable work environment, set standards, and make continuous improvements so that through the 5S methodology, management can create an environment where quality work is comfortable, clean, and safe in the organization and can optimize productivity by continuously maintaining systems in the workplace consistently [ 3 ]. The methods used are PDCA (Plan, Do, Check, and Action) and 5S. The 5S method is used to make repairs to the work station at Madani Bakery.

The 5S and PDCA methods were used. According to Houa, 5S is used to create a comfortable work environment, set standards, and improve continuously. The 5S methodology can be used to create a quality work environment that is comfortable, clean, and safe in the organization, as well as to continuously optimize productivity [ 3 ]. To identify goals, problems, and targets, the PDCA method is used. Madani Bakery has officially approved that their name will be published because Madani Bakery has improved its work culture and wants to serve as a model for other businesses.

3 Results and Discussion

Implementation at this stage, workstation documentation is carried out to identify problems that exist in Madani Bakery. Data collection of equipment used in bread production.

Plan to design improvements to reduce waste. The tools used are fishbone diagrams to identify the causes of waste. Identifying problems and designing solutions to be implemented. Fishbone diagram for transportation waste (see Fig.  1 . Fishbone diagram for transportation waste) and fishbone diagram for motion waste (see Fig.  2 ).

Fishbone diagram for transportation waste

Fishbone diagram for motion waste

Do is done to carry out repairs to the work area at Madani Bakery. Improvements were made by implementing 5S consisting of Seiri, Seiton, Seiso, Seiketsu, and Shitsuke. The goods are sorted at the work station during the Seiri or concise stage. The sorting policy is designed to determine the frequency of use of each item. Items that are used frequently or on a daily, weekly, or hourly basis are located near work stations. The goods are divided into several categories at the Seiton stage to make storage easier to determine. Each work station is given a boundary line at the Seiton stage. The boundary line is used to determine whether or not the work station is tidy. If the goods are damaged, they will be repaired (see Fig.  3 ). Seiso stage was cleaning equipment in the form of a waste basket is provided. Garbage bags are being replaced with baskets because they are more convenient to use. Other cleaning tools are adequate, but there is currently no storage space. As a result, the tool is placed arbitrarily. The work area is disorganized as a result of this condition. The provision of hangers’ aids in the organization of cleaning supplies. Hangers are strategically placed near the printing workstation.

Layout and painting strategy at madani bakery

The Seiketsu stage is carried out by making 5S reminder displays and work instructions can be seen in Table  1 . Shitsuke was carried out by making a 5S audit checklist and socializing 5S. Shitsuke is done by introducing 5S to workers at Madani Bakery. The introduction of 5S was carried out by providing material related to the history of 5S, the meaning of 5S, and forms of application of 5S in the industry. Workers who are still unsure about the 5S explanation can ask questions. Audits can be carried out directly by business owners or workers who understand field conditions. Before the audit, the auditor will be explained the audit process and fill out the checklist.

Workers are disciplined to implement 5S at the Shitsuke stage. Before attempting to build worker discipline, 5S is introduced to workers. The introduction of 5S is carried out by conducting training to ensure that all employees share the same perspective on the importance of 5S. A trainer is present to conduct the training.

The process flow map after 5S implementation shows the operating and transportation times are 773.89 and 10.49 min, respectively. The total activity after the implementation of 5S is 784.38 min. Comparison with the previous production time shows a reduction in the production time of 4.57 min. The process flow map after 5S implementation shows the operating and transportation times are 773.89 and 10.49 min, respectively. The total activity after the implementation of 5S is 784.38 min. Comparison with the previous production time shows a reduction in the production time of 4.57 min. Standardization in production activities is shown in Table  2 .

4 Conclusion and Recommendation

This study concludes that 5S was implemented at Madani Bakery by sort goods and red tags for the Seiri stage. At the Seiton stage, storage containers, item name labels, and borders are carried out. Seiso is done by providing hygiene kits and hygiene schedules. The Seiketsu stage is performed with the creation of a 5S reminder display and work instructions. Shitsuke was done by making checklist audit 5S and socialization 5S. Madani Bakery requires discipline in carrying out 5S because this is something new for workers. There was a reduction in waste from a total waste time of 12.46 min to 11,773 min. Waste reduction occurs because the goods at the workstation are neatly arranged so that it is easier to find and the existence of work instructions makes every worker have the same workflow. The advice that can be given to Madani Bakery is monitoring the implementation of 5S regularly with 5S audits and repairs if discrepancies are found at work stations so that 5S can become a work culture of Madani Bakery.

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Acknowledgments

The authors would like to thank the Department of Industrial Engineering, Faculty of Engineering, Universitas Andalas for providing publication grant 2022.

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Nilda Tri Putri, Dicky Fatrias & Santa Rosa Roberta Simbolon

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Correspondence to Nilda Tri Putri .

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Putri, N.T., Fatrias, D., Simbolon, S.R.R. (2023). 5S Implementation to Minimize Waste in Bread Production Process (Case Study: Madani Bakery). In: Kohl, H., Seliger, G., Dietrich, F. (eds) Manufacturing Driving Circular Economy. GCSM 2022. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-28839-5_40

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Table of Contents

The 5s methodology , benefits of 5s methodology: , why use the 5s methodology, before 5s implementation, after 5s implementation, implementation strategies: , 5s implementation plan, tools for 5s, 5s and lean manufacturing, implementing effective workspaces with 5s methodology.

5S is one of the first tools that can be applied in a company that is starting down the path of a continuous improvement culture. A 5S implementation helps to define the first rules to eliminate waste and maintain an efficient, safe, and clean work environment. It was first popularized by Taiichi Ohno, who designed the Toyota Production System, and Shigeo Shingo, who also put forward the concept of poka-yoke .

The 5S methodology is easy for everyone to start using. It doesn’t require any technical analysis and can be implemented globally in all types of companies, ranging from manufacturing plants to offices, small businesses to large multinational organizations — and in both private and public sectors. Its simplicity, practical applicability, and visual nature make it an engaging aid for operators, directors, and customers alike.

The 5S methodology is divided into 5 steps essential for achieving its goals. We will discuss each step in detail.

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The first step in the 5S methodology is to sort. This step involves identifying the necessary items in your workspace and eliminating any excess or unnecessary items. This helps to reduce clutter, minimize distractions, and streamline the workspace.

Set in Order:

The second step is to set it in order. This step involves organizing the necessary items logically and systematically. This includes assigning a specific location for each item and labeling them for easy identification. This helps to reduce search time and eliminate the need for excess inventory.

The third step in the 5S methodology is to shine. This step involves cleaning and maintaining the workspace. This includes regular cleaning, inspection, and maintenance to ensure everything is in working order and defects-free.

Standardize:

The fourth step in the 5S methodology is to standardize. This step involves creating a set of guidelines and procedures for maintaining the workspace. This includes documenting the previous three steps and establishing a regular schedule for their implementation.

The final step in the 5S methodology is to sustain. This step involves creating a culture of continuous improvement, where the previous four steps are consistently followed, and the workspace is continually optimized.

The 5S methodology provides numerous benefits to organizations that adopt it. Some of the benefits include:

• Improved productivity
• Reduced waste
• Enhanced safety
• Increased employee satisfaction
• Improved customer satisfaction
• Improved quality
• Reduced costs

5S is a methodology for creating an organized and productive workspace by sorting, straightening, shining, standardizing, and sustaining. Using 5S as a foundation, advanced processes and tools to implement lean production can be developed.

5S is the perfect tool to identify the first improvement projects in your company to eliminate waste. Although sometimes viewed as a housekeeping technique, it is actually an innovative management system that helps people think lean, paving the way for the adoption of Lean principles in the organization . Understanding the 5S methodology is one of the foundations of Six Sigma principles, and can be extremely beneficial for organizations of all kinds.

A Black Belt uses 5S to find waste, reorganize workflows, and promote a culture of continuous improvement as part of the Six Sigma toolbox. Their proficiency in fusing Six Sigma methodologies with Lean principles helps them to direct enterprises toward improved output and quality. A Six Sigma Black Belt starts the process of optimization by deliberately implementing 5S, laying the groundwork for extensive changes and long-term success.

And here’s the best part: implementing 5S is a breeze! With this logical, step-by-step guide, you’ll learn what the big deal about 5S is, how to devise an action plan for 5S implementation, and how best to wield this powerful tool for improved productivity , elimination of wasteful processes, and all-around development!

Pro Tip: For more on harnessing the principles of Six Sigma for workplace and personal productivity, here’s an insightful article that investigates ways to enhance performance using the principles of Six Sigma .

Implementing the 5S methodology requires careful planning and execution. Some effective strategies for implementing the 5S methodology include:

• Form a dedicated team to oversee the implementation process.
• Provide adequate training to employees to ensure that they understand the methodology and its benefits.
• Start with a pilot project and gradually expand to other areas of the organization.
• Establish clear metrics to measure the success of the implementation.
• Continually monitor and improve the methodology to ensure its effectiveness.

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Step 1: How Well is Your Business Doing?

Our cartoons above help illustrate how 5S can benefit your organization. Before you get started, let’s perform a test. If you answer yes to any of the following questions, you may find 5S really useful and effective:

• Do people in your workplace struggle to locate documents or files, whether in physical or digital format?
• Are there loose, sagging electrical cables in the workplace?
• Are there files, drawers, and cabinets that are unlabeled, or do they contain unmarked content that is hard to identify?
• Is valuable space taken up by useless items?
• Are there papers in your workplace that are not used and are gathering dust?
• Does everybody know how to keep the workplace organized and are fully aware of their roles and responsibilities?

If you answered yes to any of these questions, 5S may be exactly what you need!

Step 2: The 5S Methodology: Broken Down

What Does 5S Stand For?

The name 5S refers to a set of five terms borrowed from Japanese, all beginning with the letter S when transliterated. The equivalent terms in English also begin with an S. In essence, these five terms represent the five steps toward operational and process excellence:

Step 3: The Action Plan

You can start implementing 5S by providing training to your staff to understand the system. This may be followed up with one-day sessions with each employee or team to ensure they are on the same page as far as implementation is concerned.

In the first one-day session, employees should look be ready to meet the first three 5S requirements:

• Take a picture of the current status of your workplace.
• Sort to separate anything that is needed and necessary from what is not needed.
• Organize the things you need so that there is a place for everything and everything has a place. You should be able to find anything in just a few seconds.
• Clean the workplace and get rid of things that make it difficult to maintain cleanliness, such as boxes on the floor that prevent you from being able to clean the entire surface — label them and store them in labeled drawers, instead.
• Prepare an action plan for the items you aren’t able to deal with that day, but will be able to in the near future. This could include selling items you no longer use, donating them, recycling, or throwing them away.
• Take a second picture after the entire day’s work, for review.

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Step 4: Standardize

During the second one-day session, two weeks later, employees should take the third picture and compare it to the first two shots. Many organizations set up peer audits to check how the 5S principles are being met as well as to ensure the plan is moving forward. Work together to define ways to standardize the improvements over time: organize cleaning schedules, define roles and responsibilities, and prepare written procedures or diagrams to help everyone remember what to do.

Step 5: Sustain

During the third one-day session, two months later, check to see how your workplace looks and schedule another peer review. This way, you can make sure the 5S are sustained by ensuring defined schedules are being met and everyone is following the procedures.

• Red Tags: These are used to label items that are no longer needed or are not in use. Red tags help in the sorting process.
• Shadow boards: These are used to organize tools and equipment. The shadow board has an outline of the tool or equipment, making it easy to identify if something is missing.
• Visual controls: These are used to make it easy to identify the correct location for tools and equipment. Examples include color coding, labels, and signs.
• Cleaning checklists: These are used to ensure that the workspace is clean and tidy. The checklist helps in maintaining the shine aspect of 5S.
• Standardized work procedures: These are used to ensure that everyone follows the same process for performing tasks. Standardized work procedures help in the standardization aspect of 5S.
• Floor marking tape: This is used to mark boundaries, aisles, and storage locations. Floor marking tape helps in the set-in-order aspect of 5S.
• Kanban systems: These are used to manage inventory levels. A Kanban system helps maintain the right inventory level, ensuring no waste of resources.
• Visual management boards: These are used to display key performance indicators (KPIs) and progress toward goals. The visual management board helps in sustaining the improvements made through 5S.

5S methodology is a crucial tool within the Lean Manufacturing philosophy, which aims to maximize value while minimizing waste. The 5S system provides a structured approach to organizing the workplace, improving efficiency, reducing errors, and increasing productivity. By reducing waste and optimizing workflow, 5S supports the overall goal of Lean Manufacturing, which is to create value for the customer while minimizing resources and time. Incorporating 5S into the Lean Manufacturing process can help organizations achieve continuous improvement and sustainable success.

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1. What is the 5S methodology?

The 5S methodology is a workplace organization system that aims to improve efficiency and eliminate waste by maintaining a clean and organized work environment. The 5S's stand for Sort, Set in order, Shine, Standardize, and Sustain.

2. What is the purpose of 5S?

The purpose of the 5S methodology is to improve workplace efficiency and productivity by creating a clean, organized, and safe work environment. It aims to eliminate waste, reduce errors, and increase employee satisfaction by providing a clear and structured system for organizing workspaces and materials.

3. What is the 6th S?

While the 5S methodology traditionally consists of Sort, Set in order, Shine, standardizing, and Sustaining, some practitioners have added a sixth "S" - Safety. Safety is a critical component of workplace organization, and ensuring that employees work in a safe environment is essential for their well-being and productivity. Including Safety as the sixth "S" ensures that it is given equal importance and consideration in the overall workplace organization system.

4. How does 5S relate to kaizen?

The 5S methodology is often used as a foundational tool within the Kaizen continuous improvement philosophy. The 5S system provides:

• A structured approach for identifying and eliminating waste.
• Reducing errors.
• Improving productivity, which are all critical components of the Kaizen approach.

Using 5S supports and reinforces the ongoing Kaizen mindset of constant improvement.

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