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5S Method in the manufacturing

Manufacturing and production companies are actively seeking solutions and optimizations to streamline processes, increase safety and increase the overall quality of products. With raw materials and good workers becoming increasingly scarce and expensive, it is important to work as efficiently, safely and profitably as possible. The 5S method is a sustainable investment in structural improvement, for every maker.

5S picture

Biggest challenges in the manufacturing

Companies in the manufacturing face specific challenges. Challenges related to optimizing production processes, finding and retaining suitable personnel and reducing waste – both of materials and time. 5S Company and CI Company use the ideology of the 5S method and Lean philosophy to achieve impressive results. Based on five themes, we make the rollout and effect of the 5S method for the manufacturing and process industry transparent and tangible.

  • Skilled people are becoming increasingly difficult to find. A professional appearance helps to enthuse and seduce the right people.
  • Training courses are no longer what they used to be: companies must be able to train people (quickly) themselves
  • The new generation often wants to be 'captivated' and 'challenged' when it comes to work. In short: the work must be more fun than with the competition.
  • Producing in the Netherlands is becoming increasingly difficult with increasing labor costs and competition from low-wage countries. This makes it important not to be too expensive and to be able to deliver (custom) quickly.
  • Local production ensures a smaller footprint, but means that you have to organize processes properly in order to compete with abroad, because price remains the leading factor for many.

Concrete solutions for current themes

As a committed partner for companies in the manufacturing industry, we know what challenges companies in this sector experience. And more importantly: we have tailored our services to this in such a way that there is a suitable solution for every challenge.

Return on investment

The benefits of 5S are not always immediately visible. As a result, (higher) management sometimes does not immediately see the usefulness of process improvement and workplace optimization: ‘If it ain’t broke, don’t fix it’. Investing in something that does not immediately yield anything is a big step for many companies - especially nowadays. But, doing nothing is even more expensive. There are many hidden costs. Management sees only 4% of all problems. We work with the people on the shop floor. The people who know 100% of the problems and hidden costs.

Impact:
– Companies remain stuck in old patterns
– Disorganized and unsafe work environment
– Increase in employee dissatisfaction and stress
– Disrupted processes, longer waiting times
– Hidden inefficiency: daily problems cost unnecessary time, effort and money and, in the long term, cause frustration among employees

Solution:
A good, accessible introduction to the 5S method is to start with a small-scale process. Start with one department and maintain full control over the rollout and progress. By registering and documenting the required steps, a blueprint is created for other departments. On the basis of a audit or Gemba walk we make improvement potential visible for a 5S or CI process

Advice:
With the 5S Activation program companies are introduced to the 5S method step by step. All aspects surrounding 5S are discussed and a small work area is tackled on the work floor. The package is a small investment in getting started with 5S yourself and a practical introduction to the benefits of workplace and process optimization. The 5S Activation Program is often combined with a 5S training or 5S coaching.

5S ACTIVATION PACK

Get started with 5S at a low investment with the 5S activation package. Under the professional guidance of 5S Company. Including practical tools and specially developed software.

> ACTIVATING 5S

5S TRAINING

The 5S training is aimed at familiarizing everyone within a company with the 5S method. Work on implementing it effectively within your organization and become a star in 5S!

> CUSTOMIZED TRAINING

GEMBA WALK

The first introduction and analysis on the work floor. During the Gemba Walk, processes and waste are accurately mapped for an effective rollout of the 5S method.

> MAKE PROGRESS VISIBLE

FIRST TIME RIGHT

Customers expect products to meet all (quality) requirements. Companies trust that these products will roll off the production line the first time. 'First Time Right' is an essential condition for productivity, margins and profitability for many companies in the manufacturing industry. To guarantee output in numbers, it is not only important to work with good machines, but also to work with and retain the right people and procedures.

Impact:
– Insufficient knowledge endangers the right to exist
– Customers choose a competitive company
– Production targets are no longer achieved or improvements stagnate
– Health and stress complaints among employees
– High turnover of qualified staff
– An unattractive employer

Solution:
The 5S method makes waste visible and reduces impact on productivity. By developing employees based on 5S training, neat, organized workplaces are created within organizations and employees learn to see waste. In this way, the workplace not only becomes a pleasant and safe working environment, where employee satisfaction and improvements are stimulated, the working environment also forms a strong calling card for customers.

Advice:
5S Company and CI Company map processes well and clearly. By visualizing processes, in collaboration with management and the people on the floor, we create connections between different departments in a company. Together we work on better collaboration. Together, for the customer. These improvements contribute to the larger goal of organizations: right first time and on time.

Various 5S training courses are suitable for increasing (or refreshing) employee knowledge and effectively implementing 5S within an organization. The aim of the training is to enable employees to apply 5S in practice themselves. Because every company and every process is unique, so is every 5S approach. 5S Company and CI Company manage a process from start to finish with a hands-on mentality, including through the 5S App and 5S-audits.

5S METHOD

Separate, clean, arrange, standardize and sustain. These are the 5 S's of the 5S method. Read all about the benefits and application of the 5S method, the specialty of 5S Company.

> WHAT IS THE 5S METHOD?

5S APP

Get more insight and control over the results of your 5S deployment with the 5S App. The application supports you in securing 5S on the shop floor and easily conducting 5S audits.

> 5S-APP: IMPROVE RESULTS

5S AUDIT

Assess the 5S level of the shop floor with a 5S audit and verify that 5S has been effectively applied within the organization. Or request a 5S audit to determine the 5S level on your workplace.

> DISCOVER YOUR 5S LEVEL

lack of knowledge and time

Companies that are successful often experience rapid growth. The pressure is full on. In addition to running production and meeting deadlines, laws and regulations also play an important role within processes. In practice, sustainable entrepreneurship with a view to the environment and people often goes hand in hand with delivery. The pressure from management, the responsibility of team leaders and the execution of work by the employee: full delivery must be made every day. How does a company find the (precious) time to start with 5S?

Impact:
– If you don't make time for optimization, you lose time
– Not fully starting with workplace optimization costs time and money
– Without follow-up, 5S is forgotten or insufficiently applied
– Without assurance, 5S and Lean processes are not visible and noticeable

Solution:
5S Company and CI Company actively provide support for the entire 5S process: from Gemba to assurance. Of course, it is also possible to completely outsource the 5S implementation and have it carried out by 5S Company and CI Company. No matter who is in the lead, we keep an overview. Respectfully listening to and directing employees, consultation about planning: we remain involved in every project. We also roll up our sleeves on the work floor to ensure that the implementation is carried out as smoothly and decisively as possible. With a strong focus on drilling 5S routes, we take responsibility for your success 5S implementation.

Advice:
Special applications have been developed to ensure improvements within a company, the 5S App and the Safety App. This application provides an up-to-date and complete overview of progress and improvement, but also of disruption and waste. This input is used during audits to refocus on process improvement. We use many different methods, such as: Training Within Industry (TWI), Kaizen, Pressure Cooker and chain process simulation. By creating awareness, we get your people on board and retain your people, resulting in sustainable process improvement.

5S IMPLEMENTATION

5S can be applied to any workplace, within any industry. Find out how 5S Company helps you work more safely, efficiently and profitably. A successful 5S implementation in three phases.

> EVERYTHING ABOUT 5S IMPLEMENTATION

SAFETY APPLICATION

Lower the threshold for carrying out safety registrations and reduce the risk of accidents in the workplace with the safety app. A simple tool from 5S Company.

> REDUCE ACCIDENTS

PROCESS IMPROVEMENT

Improve the process within your organization more efficiently and faster by taking the right steps together with CI Company. Discover our experience in different industries here.

> VIEW CI-COMPANY'S EXPERIENCE HERE

improvement capacity

To achieve business objectives, every organization needs sufficient human and machine capacity. Ensuring efficient and purposeful business processes and business growth requires increasing knowledge and improving skills within the company. 5S and Lean work as accelerators of improvement capacity and contribute to achieving business ambitions.

Impact:
– Improvement is only possible with the right (internal) knowledge
– An organization is only as good as its staff
– Ensuring improvement requires good follow-up

Solution:
5S Company and CI Company map the improvement capacity of organizations. By understanding and providing insight into processes and the ‘hidden factory’ we create a roadmap for sustainable improvement – ​​both in the short and long term. Hiring an external specialist means that there is no pressure on your own organization. The consultant is in the lead, maintains an overview and is responsible for the implementation and drilling of the entire process.

5S SERVICES

There are various 5S services within 5S Company to make 5S a success within your organization. Discover the benefits of the various 5S services.

> WHAT 5S SERVICES ARE THERE?

5S PROGRAMS

A 5S rollout that meets the needs and current challenges within an organization, in order to succeed in truly efficient and safe working. And that is why 5S Company has developed various 5S programs.

> DISCOVER THE DIFFERENT 5S PROGRAMS

LEAN SERVICES

Discover more about the different methods tools we use. Starting with a Gemba walk, Strategy Deployment, Lean Roadmap, , Value stream mapping, kaizen, operational management, TWI, 5S and much more.

> VIEW CI COMPANY'S SERVICES HERE

Clear lean strategy

Successfully applying the Lean method is an important next step for many companies on the road to working more efficiently, safely and profitably. Naturally, organizations want to see results as quickly as possible before they recognize their success. Practice shows that the success of Lean is a matter of continuous improvement. Where do you want to go and what steps do you need to take to get here?

Impact:
– No good insight into (production) processes and information flows
– Choosing the wrong strategy
– Inability to recognize waste
– Incompetence in removing waste
– Connecting daily management and strategy is insufficient

Solution:
CI Company has a lot of experience with various Lean transitions and is therefore the suitable partner for supporting companies that want to integrate 'Lean' into the organization. The Lean strategy is determined together with the company, it is determined which steps need to be taken and how the entire process will be organised. CI Company bears responsibility and remains in the lead throughout the entire process.

We define the roadmap, together we walk the road to a more professional appearance. We do this at a high level, down to the last detail. The entire process is visualized from the introduction and intake. This helps to convey information clearly, so that the steps are clear and easy for everyone to understand. This is how we bring and keep people on board the Lean journey – from the shop floor to higher management.

LEAN STRATEGY

Every company is different, based on the jointly determined lean implementation strategy, which is of course 100% in line with the business strategy, the lean approach is determined, it is standardized and aligned with the strategy

> STRATEGY DEVELOPMENT

LEAN APPROACH

Our approach is structured using several successive steps. We work with the A3 way of thinking and methodology to implement, record, communicate and discuss progress on projects

> CI COMPANY'S APPROACH

OPERATIONEEL MANAGEMENT

Discussing performance and deviations on a daily basis to ensure better focus and improvements. We can help set up and coach this structure. An important ingredient to create a learning organization.

> WANT TO DISCOVER MORE METHODS?

ABOUT CI COMPANY

We guide organizations in their lean transition. Provide support from strategy development to practical implementation of improvement actions and coaching of employees. Collaborate effectively and smarter.

> COLLABORATION WITH CI COMPANY

Impression 5S in the manufacturing

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