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More information on the 7S steps
7S is a popular tool used in lean manufacturing environments and its primary benefit is its simple approach.
Phase 1 - (整理) Seiri (Sorting): This is a process to get rid of any unnecessary tools and equipment items from the workplace area. Everything else is either discarded or stored. This step is crucial to achieving greater efficiency through workplace design.
Phase 2 - (整頓) Seiton (Set in Order): This process focuses on organising work areas for maximum efficiency by organising tools & equipment to promote optimum work flows through minimising movement. For instance, all tools & equipment should be located as close as possible to where they'll be needed and processes designed to maximise efficiency. For example, if a tool is only to be used at the end of a machine, that's where it should be located.
Phase 3 - (清掃) Seisō (Sweeping): This method relates to maintaining a disciplined, systematic approach to ensure a clean & tidy workplace and tip top machines. When every shift ends, work areas are tidied and tools and equipment are returned to their designated locations. This should be carried out every day, rather than become an ad-hoc activity that's introduced when things become disorganised.
Phase 4 - (清潔) Seiketsu (Standardizing): This requires that work practices are followed in a uniform and consistent manner. Many companies have followed the first three Ss many times, only to evidence conditions slowly deteriorate.
Phase 5 - (躾) Shitsuke (Sustain the system): The process of sustaining the system is considered to be the more difficult S to accomplish. Years of experience showed that the other 4S' were not always followed. Maintaining a strong focus on this innovative method of working is essential to prevent anyone slipping back into their previous habits and ways of working. One method to sustain the system is to carry out regular audits, although care must be taken to avoid a system isn't punitive. The 6S system relies on staff involvement and commitment at every levels, and an audit that punishes people will potentially destroy any good work that should arise form the audit.
