6S: Safety

6S is the additional sixth pillar to the 5S methodology, a Lean concept that focuses on improving organization and efficiency in the workplace.

First developed by Hiroyuki Hirano of the Toyota Motor Company, the steps of 5S are defined as:

The sixth S stands for Safety and has recently become a new aspect to the 5S method. Issues with safety can be very wasteful and cause delays or defects in the production process, so implementing a safety program can enhance an organization’s 5S success. To do this, many companies regard safety as having an integral role within each of the five steps; although it is listed at the bottom, Safety is not often regarded as its own individual step at the very end and instead is commonly applied throughout 5S.

6S can be beneficial to a wide variety of industries. Although it is mainly used in manufacturing, it has helped health care facilities, offices, and repair facilities increase their overall efficiency and reduce waste. The concept is not just about cleaning your workspace; it’s an entire framework that emphasizes specific tools and cultivates a certain mindset in order to achieve efficiency, while practicing safety at every step along the way. Using this methodology requires the participation and ongoing effort of each worker, no matter what their role is within the business. Once 6S becomes a daily habit for everyone, your facility is well on its way to becoming more efficient, productive, and safe.

Tips for Implementing Safety into the 5S Framework

Safety plays an essential role in 5S, since it’s a key component to a variety of work practices. By cleaning regularly, organizing materials, and implementing standardized procedure, you make it safer for workers to navigate the worksite and perform their jobs.

Here are a few tips to emphasize safety in each of the five steps:

6S Lean Requirements

To successfully implement the 6S lean approach in your workplace, you'll need:

1. A deep understanding of and experience with the 5S methodology, which involves organizing and maintaining a clean environment.
2. A well-established system to identify and report any potential risks and dangers in the work area.
3. Comprehensive safety awareness training relevant to the requirements of your industry.
4. Regular discussions about 5s or 6s with your team to keep the workplace organized and efficient.
5. The full support and approval from your upper management, along with dedicated resources.

The Importance of 6S for Workplace Optimization

Adopting the key principles of six S - which involve Sort, Set in Order, Shine, Standardize, Sustain, and Safety - can bring substantial benefits to organizations, and these include increased efficiency, improved safety of employees, reduced waste, and better communication among the workforce.

These steps help create a workplace that is neater, cleaner, and better-taken care of, which makes people work better and reduces the chance of accidents and injuries.

Implementing safety measures also helps protect the wellbeing of workers, which is absolutely crucial. Beyond the initial benefits of better efficiency and protection, the 6S also enables continuous improvement in the long run.

By setting clear ways of doing processes and encouraging everyone to take responsibility, companies can make sure that these vital principles become a regular part of daily operations and workflows in the workplace.

Benefits of 6S

Using the 6S approach at work can bring many great benefits, positively impacting overall operations and productivity. Here are some of the main advantages of implementing this system:

Higher Efficiency and More Productivity

The main goal of using the 6S method is to simplify work processes and get rid of wasteful activities. This is done by sorting out items that aren't needed, arranging necessary ones, and setting up standards for procedures, which create a more effective work environment. When employees can easily find the necessary tools, they won't waste time searching. This lets them focus more on tasks that add value to the company, resulting in improved overall productivity.

Cost Savings and Better Waste Management

This methodology helps people recognize and get rid of things that aren't needed (waste), whether it’s unnecessary inventory, slow processes, or resources that aren't being used well. When companies do this, they can save money by managing their materials better and reducing waste, leading to lower costs.

When a workplace becomes more organized and efficient, it's easier to manage supplies and reduce your storage requirements. This means they can use their materials and equipment, all of which contribute to lower expenses in daily operations.

Increased Production Quality

When a workspace is neat and organized, it's safer and easier to reach the components you need, and this makes it easier for manufacturers to focus on making high-quality products. If they use inspection softwares to check if they're following the 6S approach, they can also use it for quality checks. This helps them keep their customers happy and their business successful.

Reduced Workplace Risks

Safety is a key part of the 6S. When organizations follow this rule, they can find and address any dangers in the workplace. This could mean storing harmful materials safely, keeping walkways clear, and giving workers the personal protective equipment (PPE) gear. By doing this, they can reduce accidents, injuries, and time lost at work. They can also create a culture where safety is important, which helps keep their employees healthy.

Improved Communication and Teamwork

When employees work together to apply the 6S method, they can improve their communication and teamwork. As they sort, organize, and establish rules for their work area, they develop a shared understanding of their jobs and what they need to do. This helps them work together better, solve problems, and feel more connected to their work, which leads to better morale, job satisfaction, and overall unity in the team.

The 6S Argument: Should It be an Individual Pillar?

There is some controversy and confusion surrounding 6S and its place within the 5S concept. The ultimate goal of adding Safety as a sixth pillar is to eliminate risks and hazards throughout the 5S process. However, many people argue that practicing safety is already an inherent part to much of 5S, especially within the Set in Order and Shine steps, and it does not need individual focus. Additionally, with compliance to safety standards set by OSHA, NFPA, ANSI, and others, protection against injuries and illnesses is a large aspect to the workplace and a safety pillar/standard may be redundant.

Some Lean professionals choose to leave out Safety when they implement 5S programs into their workplaces, mainly because they do not wish to cause confusion and make workers think that Safety is a separate step that doesn’t need to be considered until all the other 5S pillars are addressed, due to the fact that Safety is often listed last. Others believe that 5S and safety are most effective when they are kept simple and separate, with the purpose of each clearly distinct.

To determine whether implementing 6S in your workplace and adding that sixth pillar is the right call for your facility specifically, take into consideration the work culture you currently have and the culture you are attempting to create. While practicing safety can indeed promote efficiency and reduce waste, it may also lead to lost time and reduced efficiency, if, for example, you work in an office environment or other type of workplace that does not typically experience a high occurrence of hazards.

Could your workplace benefit from 6S? Are there ways you could use Safety to not only protect workers, but increase productivity and performance within your facility overall? Safety can be an essential component to the 5S methodology, but since every workplace is different, it may take some trial and error before you find the best way to implement this concept in your situation.