6S: Safety

6S is a workplace organization methodology that builds upon the 5S system, with the addition of “Safety” as the sixth principle. Many workplaces focus on enhancing their systems to drive productivity and efficiency, often missing an integral component of safety in their natural processes. The primary objective of 6S is to establish a workplace where safety is paramount while maintaining efficiency and productivity.

6S Pillars

The sixth S stands for Safety and has recently become a new aspect of the 5S method. Issues with safety can be very wasteful and cause delays or defects in the production process, so implementing a safety program can enhance an organization’s 5S success. To do this, many companies regard safety as having an integral role within each of the five steps; although it is listed at the bottom, Safety is not often regarded as its own individual step at the very end and instead is commonly applied throughout 5S.

6S Across Different Industries

The 6S methodology is not reserved for a particular industry; rather, it can be optimized through different sectors to ensure a safe and organized working environment.

6S in Manufacturing

6S in manufacturing is an approach that is used to drive profitable results like enhanced productivity and eliminate hazards that workers in manufacturing industries face. By incorporating the 5S principles (Sort, Set In Order, Shine, Standardize, and Sustain), along with the additional factor of Safety, workers can focus on their tasks without compromising their safety.

For instance, workers are often exposed to manufacturing issues, such as heavy machinery malfunctions, that threaten their safety. Testing the machines (Sort) and segregating functional machines from those with failures or broken parts can help create safety in manufacturing industries. Remember that safety is not a standalone component; rather, it must be consistently implemented throughout the 5S methodology.

6S in Management

6S is an extension of the 5S methodology, commonly used in management sectors to enhance operational efficiency, product quality assurance, and establish smooth standardized procedures, with an added emphasis on safety. Management sectors can greatly benefit from incorporating the 6S system, which can aid in planning, organizing, controlling, and evaluating their established goals.

For instance, by implementing the first principle of 6S, companies can sort through short-term and long-term goals and evaluate where to invest their resources and funds in a particular project based on the gains they’ll receive. With the added safety component, this approach can help employees recognize hazards that compromise their safety and cultivate a culture of well-being.

6S Lean Requirements

To successfully implement the 6S lean approach in your workplace, you'll need:

• A deep understanding of and experience with the 5S methodology, which involves organizing and maintaining a clean environment.
• A well-established system to identify and report any potential risks and dangers in the work area.
• Comprehensive safety awareness training relevant to the requirements of your industry.
• Regular discussions about 5s or 6s with your team to keep the workplace organized and efficient.
• The full support and approval from your upper management, along with dedicated resources.

Examples Of 6S

Many workplaces have adopted the 6s methodology to improve employee productivity and develop a system meeting safety standards. One of the common examples of practicing 6S in healthcare facilities can be used to organize medical supplies and establish sanitary checks to ensure patient and healthcare professionals' safety.

Benefits Of Implementing 6S

Higher Efficiency and More Productivity

The main goal of using the 6S method is to simplify work processes and get rid of wasteful activities. This is done by sorting out items that aren't needed, arranging necessary ones, and setting up standards for procedures, which create a more effective work environment. When employees can easily find the necessary tools, they won't waste time searching. This lets them focus more on tasks that add value to the company, resulting in improved overall productivity.

Cost Savings and Better Waste Management

This methodology helps people recognize and get rid of things that aren't needed (waste), whether it’s unnecessary inventory, slow processes, or resources that aren't being used well. When companies do this, they can save money by managing their materials better and reducing waste, leading to lower costs.

When a workplace becomes more organized and efficient, it's easier to manage supplies and reduce your storage requirements. This means they can use their materials and equipment, all of which contribute to lower expenses in daily operations.

Increased Production Quality

When a workspace is neat and organized, it's safer and easier to reach the components you need, and this makes it easier for manufacturers to focus on making high-quality products. If they use inspection software to check if they're following the 6S approach, they can also use it for quality checks. This helps them keep their customers happy and their business successful.

Reduced Workplace Risks

Safety is a key part of the 6S. When organizations follow this rule, they can find and address any dangers in the workplace. This could mean storing harmful materials safely, keeping walkways clear, and giving workers personal protective equipment (PPE) gear. By doing this, they can reduce accidents, injuries, and time lost at work. They can also create a culture where safety is important, which helps keep their employees healthy.

Improved Communication and Teamwork

When employees work together to apply the 6S method, they can improve their communication and teamwork. As they sort, organize, and establish rules for their work area, they develop a shared understanding of their jobs and what they need to do. This helps them work together better, solve problems, and feel more connected to their work, which leads to better morale, job satisfaction, and overall unity in the team.

How To Incorporate The Element Of Safety In 6S Lean

Safety is essential in 5S and is a key component of various work practices. Cleaning regularly, organizing materials, and implementing standardized procedures make it safer for workers to navigate the worksite and perform their jobs.

Here are a few tips to emphasize safety in each of the five steps:

Sort

Cluttered worksites interfere with performance and present various hazards. Items on the ground can cause slips, trips, and falls, while things stored out of reach can further endanger workers. Organizing the workspace encourages efficiency and creates a much cleaner and safer environment.

As you determine what is unnecessary, you may encounter tools or equipment that have been unused for a long time. and pose a danger For example, old machines may have exposed wires or no protection against pinch points. Keep an eye out for necessary items that may be more than just taking up space—they could potentially pose a threat to safety as well.

Set in Order

As you set equipment and tools in their logical place, keep safety in mind. Will a worker have to dangerously work their way around something to reach a tool? Is there a situation in which they have to leave equipment unsupervised as they search for the items they need? Sometimes a matter of safety is the biggest factor in determining an item’s proper place.

This step also involves labeling, which provides an excellent opportunity to evaluate and label potentially unsafe spaces, hazards, or dangerous chemicals in the area. Visual communication is an important aspect to both safety and efficiency. As they Set in Order, many facilities implement new signs and labels or update their existing communication system.

Shine

Once a workspace has been sorted and set in order, it needs to be fully cleaned and sanitized. This involves vacuuming, scrubbing, and other types of sanitation to completely remove accumulated dirt and grime. This keeps equipment in working order and reduces the risk of illness or injury from occupational exposure. It is especially important in environments that deal with hazardous substances or chemicals to ensure that the area is completely clean.

An important aspect of the Shine step is to conduct machine and equipment inspections and make sure they are functioning safely and properly. Consistent maintenance keeps machines in working order. Not only does this save the company money in the long run by preventing breakdowns and defects, but it also prevents personal injuries that may be caused by equipment malfunctions.

Standardize

When you incorporate a consistent 5S system into your workplace, this allows 5S to become an aspect of daily operations. Standardizing your Sort, Set in Order, and Shine procedures ensures that all efforts to increase efficiency can be practiced for the long term. As you reach the Standardize step, now is the time to implement a universal system so employees understand what they need to do. Audit sheets and checklists make sure that daily 5S processes are carried out as they should be.

By implementing a company-wide standard for safety, you can make sure that workers stay safe no matter what shift they’re on or what type of tasks they perform. Standardizing means that everyone does things the same way—and enforcing universal guidelines is one of the best methods available to ensure that people are not harmed within your facility. It also makes it easier to stay OSHA compliant and reduces the risk of violations and financial penalties.

Sustain

Improvement that is sustained over time leads to a more efficient and safer workplace. The final step attempts to take each pillar and transform them into continual habits that workers incorporate into their daily tasks. While this is not going to happen overnight, it is well worth the effort.

There are a wide variety of tools available that you can use to support your Sustain efforts: remind workers of each step with 6S banners, and keep a steady supply of 6S red tags on hand. This emphasizes the fact that your workplace values organization and efficiency as it continues to implement 6S and keeps workers informed as they attempt to uphold the six pillars each day.

Safety is also an ongoing practice that should be incorporated into both a workplace’s culture and people’s mindsets. Practicing safety is a daily effort. Remind workers to stay safe and protect themselves through 6S visual cues like wall signs that remind workers to clean up after themselves or floor tape that indicates a hazardous area.

Implement 6S Into Your Workplace With Creative Safety Supply

Foster a culture of safety with Creative Safety Supply, your one-stop shop for quality, high-grade industrial safety signs and comprehensive guides. Whether you’re the supervisor of a manufacturing floor or part of a management company's planning department, implementing the 6S system can benefit every sector. To help you incorporate an extra layer of safety, we customize 6S signs to help reflect safety in your terms!