Applying Lean Manufacturing 5S methodology to Information Systems (Manufacturing Operations Management Talk)

While we are going around making the plant shine with 5S initiatives in every department, why not apply some of the same principles to the information systems?

5S focuses on effective workplace organization and standardization.The goal of 5S is to simplify the work environment and eliminate distractions to improve quality, efficiency, and safety. The name “5S” is based on the following five Japanese words in parenthesis that begin with S: Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain).

Sort – Focuses on eliminating unnecessary items from the workplace. Review logs and reports used on the shop floor periodically and determine if they are still necessary. Remove or replace obsolete manuals collecting dust on the shelves. Use value stream mapping to identify wasteful steps in the information flow, red tag them and start initiatives to eliminate them. Application screens used by the mechanic on the shop floor should remove information that is not really needed to perform the job.

Set in Order – Organize the flow of information on the shop floor along with production. Designate areas for charts on bulletin boards, label areas for manuals. Minimize paperwork that travels with the product and standardize how identification and information will be attached to the product or transportation bin. Procedures should be simple and clearly identify the next step. For online information, make sure that the mechanic’s screen is simple with clear menu choices for online documentation required to perform the job.

Shine – Post responsibility and schedule for inspection and update of logs and manuals used on the shop floor. Periodically audit procedures with shop floor personnel and update procedures if required. Everyone on the shop floor should participate and provide feedback. Everyone should be proud of the procedures used on the shop floor or should be supporting initiatives to improve the procedures.

Standardize – Derive standards, patterns and models for best practices that can be applied to other areas. Establish a central shared repository for these best practices with change control and governance procedures.

Sustain – Focuses on developing a methodology for sustaining the improvements made using the first four steps. Take extra effort to publicize the standards published and the achievements of different areas. Motivate initiatives for knowledge transfer to improve other areas and maintain a cycle of continuous improvement process throughout the company.

Should we apply 5S at the office, at home? Let’s not get carried away :-)

References:

I’m collaborating on a new guidebook that will be published by the MESA organization: “MESA
Lean Manufacturing Strategic Initiative Guidebook.” Please visit http://www.mesa.org for more information on this guide which is full of great process improvement ideas. Joining the MESA organization is easy and gives you access to great information.

For more information on 5S visit: http://en.wikipedia.org/wiki/5S_(methodology)