Project of the Month


"Time to Dust Off Your 5S Program!“

Be honest: When was your last 5S audit?

KENNZAHL


  • Audit results before: Ø 82% 
  • Audit results afterwards: 73% 
  • On restart: 81% 
  • Target Ø over 90% 

INITIAL SITUATION


During the COVID-19 pandemic, many companies shifted their priorities due to increased demand, often sacrificing efficiency for short-term production gains. The mantra was frequently in the furniture, caravan, and broader woodworking industries: "More output, no matter what."

Given current economic pressures, refocusing on efficiency and workplace organization is more critical than ever. Minor oversights that crept in during the hectic pandemic years must now be addressed to maintain long-term competitiveness.

With declining revenues and softening demand, reviving and consistently applying proven methodologies like the 5S concept is crucial.

STRATEGIC APPROACH


While the 5S concept is widely known, well-documented, and extensively implemented, our focus here is on revising and evolving existing systems to optimize them and bring them back to the forefront. The following steps, based on the 5S methodology, help identify neglected areas and realign them with original standards:


  1. Sort (Seiri)
    Take a fresh look at everything accumulated in your workspace during the pandemic. Evaluate all materials, tools, and information with a critical eye. Remove items that need to be regularly used or have become redundant. Document these decisions to prevent the future accumulation of unnecessary items.
  2. Set in Order (Seiton)
    Analyze how workflows and requirements have evolved since the pandemic. Previous organizational systems might no longer serve your needs. Adjust your workplace organization to reflect current operations, implementing visual management systems that support today's workflows.
  3. Shine (Seiso)
    Establish precise cleaning and maintenance protocols that go beyond basic housekeeping. Create specific standards for different areas and equipment types, with assigned responsibilities and regular monitoring. Cleaning and maintenance are integral parts of daily operations.
  4. Standardize (Seiketsu)
    Review and update existing standards to match current operational needs. Create clear documentation with visual aids, implement effective training programs, and establish metrics to measure success. Regular reviews ensure standards remain current and effective.
  5. Sustain (Shitsuke)
    Understand why standards were previously neglected and address these root causes. Implement regular training, create recognition programs, and ensure visible leadership engagement through regular audits and continuous improvement activities.
    

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