Introducing the 5S Lean Principles of: Seiri, Seiton, Seiso, Seiketsu and Shitsuke (Sort, Set in order, Shine, Standardise and Sustain). Now referred to as 6S Lean or 5S + Safety.

5S is a framework for operational efficiency. It is used by organisations across the world to eliminate waste, uphold health and safety standards, and cultivate an environment of unrivalled productivity.

More recently, the framework has been expanded to include an additional principle and is now referred to as 6S Lean or 5S + Safety. The six principles are listed below:

  • Seiri: Sort
  • Seiton: Set in order
  • Seiso: Shine
  • Seiketsu: Standardise
  • Shitsuke: Sustain
  • + Safety

Where do the 5S Lean Principles come from?

Developed in Japan, there are two popular origin stories for the 5S Principles. One theory is that the concepts underpinning the 5S framework were established by 16th century Japanese shipbuilders, with their streamlined assembly process allowing ships to be built in a matter of hours.

An alternative view is that the 5S Principles were only officially introduced by Toyota in the 1970s when its analysts were sent to dissect the assembly line of rivals: Ford Moto Company. Based on these findings, Toyota formulated a methodology to surpass its competitors.

When did the 5S Lean Principles become 6S Lean or 5S + Safety?

Over time, the 5S Principles have evolved to become 6S, otherwise known as 5S + Safety. Although some organisations still work with the 5S framework, businesses that face significant on-site risks have embraced the new principle of ‘Safety’ in an effort to highlight its importance.

The principle of ‘Safety’ is particularly relevant to the food production industry, as it is incredibly important when it comes to the protection of both site staff and consumers. That is why an increasing number of sites regard 6S Lean as their preferred workplace improvement process.

What exactly are the 5S Lean Principles? Now popularly referred to as the 6S Lean Principles or 5S + Safety.

Seiri: Sort

Establish what equipment is required and remove anything that is unnecessary.

Seiton: Set in order

Create a home for each item with the use of suitable storage solutions e.g. shadow boards.

Seiso: Shine

Ensure working areas are cleaned regularly and kept free from clutter.

Seiketsu: Standardise

Implement the same improvements across all areas of your site and all departments.

Shitsuke: Sustain

Assign responsibility for the continual maintenance and review of standards.

+ Safety

Eliminate hazards to reduce the risks of accident, injury, or consumer-related incidents.

How can the 5S Lean Principles
(6S or 5S + Safety) help your business?

5S Lean (6S or 5S + Safety) has already gained a lot of traction in the food production industry. And for good reason, with research highlighting the effectiveness of this framework, along with the many benefits it can deliver:

  • Happier staff: your team will appreciate your efforts to make their job easier through a more pleasant and manageable work environment.
  • Amplified productivity: logical workspace organisation decreases downtime and time-consuming misunderstandings. It's also true that happier teams are more productive.
  • Tidier and safer workspace: Sorting (Seiri) and Shining (Seiso) make your workspace tidier, helping to eliminate health and safety risks. This also relates to the + Safety principle.
  • Better quality and lower prices: increased efficiency makes your products more consistent and of better quality, resulting in increased profits, as well as the option to reduce prices for your loyal customer base.

How can you implement the 5S Lean Principles (6S or 5S + Safety)?

1. Sort (Seiri)

Carrying out a regular equipment audit will allow you to identify tools in need of replacement long before they pose a food safety risk. It is also the perfect opportunity to remove unnecessary equipment that has the potential to cause confusion or would be better served elsewhere on your site.

With auditing bodies such as BRCGS placing increased emphasis on the importance of suitable and hygienically designed equipment, the effective management of the equipment at your food factory has never been so important. Luckily, the principle of Seiri (sort) will help to make this happen.

2. Set In Order (Seiton)

Consider the layout of your site. Are your team walking back and forth from their designated work areas to collect and return utensils?
Do your operatives waste precious time and energy searching for the tools they need?

The principle of Seiton (setting in order) ensures equipment is where it should be at all times. It can be supported by our range of shadow board solutions and tool stations – printed with customisable shadows for your choice of utensils and fitted with hygienically designed hanging hooks to keep your tools safely off the ground.

Examples of shadow boards and equipment storage systems used in food production facilities

Shadow board Inspiration Guide

Want to learn more about shadow boards? From engineering tool boards and storage for your spill kits to PPE bases and change part stations, there are over 70 shadow board designs to explore in our Inspiration Guide.

3. Shine (Seiso)

Working within the food production industry, you will already be well-aware of the importance of cleanliness and hygiene. After all, this is an integral part of protecting your operatives and customers, not to mention securing that all-important audit compliance. Standard hygiene practices such as scheduled wash-downs, clean-as-you-go policies, black bag audits, internal audits, and the ongoing training of site-staff will help you to drive standards in this area. Along with the safety of your operatives and consumers, Seiso (shine) should also extend the lifespan of your equipment and machinery.

4. Standardise (Seiketsu)

5S Lean Principles

The first step in standardising the processes at your site is to write down what is being done, where it is being done, and who is doing it. This will make it easier for you to incorporate new practices into normal work procedure, paving the way for long-term change.

Before establishing any Standard Operating Procedures (SOPs), you will need to observe your team – identifying where problems arise and which methods work most consistently. Consult employees to double-check each stage, and ensure the process feels natural.

Our range of Visual Management Solutions could help to raise awareness of any new or updated SOPs at your site. Below are three examples to consider:

5S (6S Lean or 5S + Safety) Checklists: listing the individual steps of a process makes it easy for workers to follow the relevant instructions. It also provides a simple Visual Management Tool that can be checked by team leaders.

Job Cycle Charts: identify each task to be performed and establish the frequency. Then, assign responsibility to a particular operative or team. The resulting chart can be turned into a Visual Management Board that helps to resolve questions and encourage accountability.

Procedure Labels and Signs: ensure Operating Instructions, Cleaning Steps, and Preventative Maintenance Procedures are clearly visible at key areas of your site.

5. Sustain (Shitsuke)

Implementing the 5S Lean (6S or 5S + Safety) Principles is an ongoing process.

In fact, the framework is most effective once it has become a core part of your company culture. To make this happen, you will need to prioritise the following areas:

  • Management Support
  • Department Tours
  • Updated Training Procedures
  • In-House Progress Audits
  • Performance Evaluations

6. + Safety

For a lot of businesses, safety is viewed as an over-arching principle that relates to every application, area, and team member.

From appointing Health and Safety representatives and carrying out internal health and safety inspections to focusing on root cause analysis and embracing the principle of continuous improvement, there are plenty of opportunities for you to make safety a priority at your site. You should also find that prioritising safety helps you to achieve key milestones surrounding Sort, Set in Order, Shine, Standardise, and Sustain.

We hope this article has provided you with a greater understanding of the 5S Framework, now commonly referred to as 6S Lean or 5S + Safety.

If you would like further support as you implement these principles at your food production site, you can connect with one of our consultants on 01473461800 or sales@klipspringer.com.

Alternatively, you can fill out the contact form below and one of our friendly team members will be in touch. 

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