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5S is operations discipline, the 5 Why is part of the problem solving process that helps to implement it.
There are many misconceptions about 5S, but it is more than just clearing up.
First S = Sort = EMPOWER the cell operators to remove unwanted / unused equipment and design the work space / work flow inline with Takt time.
Second S = Set in Order = work with engineers / managers to develop their work space inline with the requirements for Takt time. This provides TEAMWORK because the operators cannot move equipment or develop the ergonomics without help; usually there are fabrications or purchases of equipment or tooling.
Third S = Shine & Inspect = The first step in Autonomous Maintenance. The operators should be trained to detect abnormalities with their process and report them to maintenance. They should also be trained to do their own basic maintenance and lubrication. This entails keeping the process and work space in design standard which builds OWNERSHIP.
Fourth S = Standardise = This is a MANAGEMENT function to ensure that the same standards are applied throughout the value stream.
Fifth S - Sustain - This is the key to 5S and is the DISCIPLINE. The senior manager undertakes weekly 5S audits; helps operators to correct faults and return to standard or takes remedial action with "anchors" who refuse to adhere to the policy.
5S is used to change the culture in a business; to burn the bridges of what has happened in the past and to install discipline. It is a management tool to get the workforce to do what it wants them to do when it wants them to do it. There are physical changes to the work place so there are no emotional hooks to the past.
Unfortunately most companies do not get past 2S and so everybody thinks that it is just a cleanup exercise.
No,
5S is: To Organize and Maintain the Work Place to be MORE PLEASURE, MORE EASY, MORE EFFECTIVE, MORE SAFE.
Why-why analysis is carried out to find out the root cause of reoccurring issue of equipment failure.
5S & Why-Why analysis is complementing to each other but have importance separately as well.
5S ', NOT ONLY MEANS cleaning, is much more, is order, is to know How to use Materials and Tools avoiding accumulation of waste,5S, is to reduce incidents to avoid accidents,5S is self control, change of Attitude, discipline, Collaboration
Nio, 5S system is not a housekeeping program, it is a problem prevention and problem identification system so, when 5S shows us something out of place, the process should be to repeatedly ask why until we find the root cause and take action.
