Operational Excellence - The Power of 5S
It’s hard to believe a system developed more than 70 years ago in post-war Japan for a car company sits at the forefront of contemporary operational excellence for efficiency, productivity and profitability. But few methodologies have left as indelible a mark as the 5S warehouse system which provides a framework for organising, cleaning, developing, and sustaining a productive work environment. In the current dynamic business landscape this system continues to revolutionise workplace organisation; a fact which is especially true for commercial warehouse installations where seamless operations directly impact productivity and profitability.
Where did 5S originate?
Developed by Sakichi Toyoda and Eiji Toyoda along with Japanese industrial engineers in 1950s Japan, 5S was originally known as the Toyota Production System and helped that company become one of the top car manufacturers in the world. At the heart of Toyota’s transformation was the concept of "lean manufacturing," a philosophy that sought to eliminate waste and optimise processes through continuous improvement. But there is a science and an art to it. The specialised system adheres to five Japanese principles.
The five pillars of 5S
Central to the TPS philosophy is the notion of "jidoka" (automation with a human touch) and "Just-in-Time" (JIT) production, principles that emphasized quality, flexibility, and efficiency. As Toyota's production system evolved, it became clear an organised and clutter-free workspace was essential, which lead to the foundational principles of 5S—Sort, Set in Order, Shine, Standardise, and Sustain.
1. Sort comes from the concept of "seiri" (sorting) in Japanese which promoted the removal of unnecessary items from the workspace. By decluttering and eliminating excess inventory from work spaces, Toyota's workers were able to optimise the use of their areas and reduce waste. This is a principle which remains central to the 5S methodology today.
2.The second "S," Set in Order, or "seiton" in Japanese, focusses on organising tools, equipment, and materials in a logical and efficient way. By assigning clear locations for these items and bringing in visual management techniques such as shadow boards and colour-coded labels, Toyota's engineers were able to streamline workflows and minimise wasted time searching for tools or parts.
3.The third "S," Shine, or "seiso," emphasizes the importance of cleanliness and maintenance in the workplace. The Toyota team realised regular cleaning and inspection of equipment not only ensures a safe and hygienic work environment but also helps highlight potential issues before they escalate into expensive problems.
4.Standardisation is the fourth "S" and is derived from "seiketsu." This involves initiating protocols and procedures to maintain the gains achieved through the previous steps. By documenting best practices and creating standardised work instructions, Toyota was able to ensure consistency and efficiency across its production facilities.
5.The final "S," Sustain, or "shitsuke," represents commitment to continuing the 5S principles as an ongoing process rather than a one-off. Through training, communication, and reinforcement of 5S principles, Toyota was able to embed a culture of continuous improvement into its organisational DNA. This was a culture that would become synonymous with the company's success.
Sydney warehouse, March 2024. Photo: Jack Carter
How did the 5S concept spread across the world?
By the 1970s the system had been picked up by other Japanese industries including banking, healthcare and government. The English-speaking press started to take note of the concept and 5S went on to become a key component of the “lean manufacturing” wave which spread through the west via the U.S and Europe in the 1980s.
Today, the 5S warehouse system stands as a cornerstone of this ongoing lean management practice. It provides organisations with a proven framework for enhancing efficiency, organisation, and workplace culture. It has application not only in warehouse settings but has also been employed by software designers and architects including domestic designers.
What is the 5S tape system?
It seems simple enough. High performance floor marking which brings the 5S system to life and which provides an efficient way to direct behaviour, promote safety and to reinforce workplace standards and efficiency. Coloured floor tape and markers which highlight workflow patterns, delineate work areas and mark correct placement of tools and machinery. It’s a back to basics approach which if you get right at the start, can revolutionise organisational efficiency in a commercial warehouse setting.
Sydney warehouse, March 2024. Photo: Jack Carter
The Purpose of 5S tape
Visual Communication: 5S tape serves as a visual communication tool, guiding employees on where items should be placed, where equipment should be stored, and where movement should occur within the workspace.
Safety Enhancement: By delineating pathways, hazardous zones, and emergency exits, 5S tape improves safety in the workplace by identifying safe walking areas and potential hazards.
Organisation and Efficiency: Floor marking with 5S tape contributes to overall organisation and efficiency of the workspace, helping to maintain order by clearly defining storage areas, work zones, and production areas, facilitating smoother workflows.
Compliance and Standardisation: 5S tape aids in standardising processes and procedures by ensuring consistent placement of tools, materials, and equipment.
Types of 5S tape
Colour-Coded Tape: Different colours of tape can represent different meanings or instructions.
Floor Marking Shapes: In addition to solid lines, 5S tape may come in various shapes such as arrows, corners, and T-junctions. These shapes are used to convey specific messages.
Reflective Tape: Reflective 5S tape is often used in low-light environments or areas with heavy machinery to enhance visibility and safety.
Sydney warehouse, March 2024. Photo: Jack Carter