For facility operations managers, initiating a 5S lean manufacturing program can reduce waste and boost productivity through better workplace organization. With each S (Sort, Set in order, Shine, Standardize, and Sustain) accounting for a separate 5S stage, the process can seem like frustrating, but does not have to be.
 
“You don’t have to get the 5S process perfect right away,” says Tina Huff, Group Product Manager at Avery Products Corporation, a commercial and industrial label manufacturer. “Just get started and keep improving over time.”
 
Because nothing is set in stone, using industrial brands for organization and identification that are created to be utilized and removed, as well as customized, can help to boost each single stage of the process.
 
Sort
 
The first 5S stage, Sort: purges clutter and unneeded goods from the work area. This leaves just the parts, tools, machines, and supplies important for daily use on the manufacturing or warehouse floor. In this phase, impermanent labels can be put on items as the facility’s staff sorts through them.
 
“One method is to mark items as TBD, and then wait a month or so,” says Huff. “When you use an item, consider how it’s used or who uses it to determine its permanent home. If you haven’t used it in that time, consider discarding it.”
 
For greatest results, ensure that to use labels that are won’t fall away during the Sort stage, however try not to cause damage or leave behind residue when you need to remove them.
 
Set in Order
 
The second stage, Set in order: locates parts, people, tools, and equipment in the most efficient, ergonomic positions, so operators do not waste time or effort searching for needed items.
 
To increase workplace productivity, identification labels can be built in to identify and classify parts, tools and equipment, so items are readily accessible and everything has a home. Racks, shelves and cabinets also make sense to label, as do smaller portable items like bins, totes and toolboxes, which help with organization.
 
Color coding labels can add another level of organization to items. With labels that are printed on a laser or inkjet printer, it is simple to include color, icons or even photos on labels. This makes it easier to quickly identify items and determine where they belong.
 
Shine
 
The third stage, Shine: makes sure the workplace stays totally free of clutter, grime and malfunction. This helps for preventing serious work breakdowns or slowdowns. In this process, cleaning and inspecting through cleaning is critical. Then again, labels that are not lasting can get torn or otherwise unreadable, which is a particular problem with barcode labels.
 
“During inspection, it’s good to replace any damaged or inaccurate labels,” says Huff. Also, keep track of machine maintenance with inspection labels so routine maintenance isn’t forgotten. This helps to prevent costly downtime and improve safety by reducing malfunction related accidents. Be sure that there's a process in place so whoever is responsible knows which machines they need to examine, and how frequently. A good inspection label will include areas for marking the date and person who conducted the inspection.
 
To reliably perform through the Shine stage, however, it is significant to create ID labels that are designed to withstand daily wear and tear, dirt, grease, oil, chemicals, and wash downs while providing good barcode readability.
 
Standardize
 
The fourth stage, Standardize: systematizes the most beneficial work methods with clear standards. Utilizing schedules, checklists and standard operating procedures are an integral part of this process.
 
Without standard operating procedures and clear processes, a facility will not run consistently and properly, even if everything is labeled accurately. Wherever possible, it is useful to place procedures and checklists on labels posted near work areas.
 
Sustain
 
The fifth stage, Sustain: trains and maintains company standards and procedures until they end up a habit and are continually followed. Because 5S is a continuous process, however, organizations will reorganize or improve processes throughout the year, as well as accommodate changes in data, format, and regulation.
 
In this case, easily removing old labels and printing custom, updated ones can be important. If not, employees can spend time tossing old labels off, using heat guns or even razor blades. They may be hesitant to update labels if it is difficult to get the old ones off, so may make do with sub-standard situations.
 
The ideal solution would be to use industrial labels for organization and identification that are very easy to adhere, resilient enough to endure harsh conditions, yet be removed cleanly when necessary, leaving no trace.
 
Available in a variety of sizes, they print easily on standard laser or inkjet printers, enabling custom, do-it-yourself labels for signs and identification. The company’s free online Design and Print Software allows customizable printing utilizing OSHA/ANSI compliant and 5S templates. Employees can create and print their own informal, official, or compliant labels from pre-designed templates or create them step-by-step at their desk. Employees find the process intuitive, since it resembles creating an office document from pre-designed templates.
 
To accommodate warehouse settings, the software’s barcode generator makes it easy to add text, graphics, serialized numbers or barcodes in a few steps. The combination of a bright white label material with superior ink/toner anchorage further enables accurate barcode scanning, even at extended distances.
 
With all the equipment, supplies, racks etc. used in industrial settings, the ability to conveniently print new 5S sign and identification labels in minutes, while being able to cleanly remove the old, will go a long way toward keeping facilities efficiently up to date without the hassle, mess, or cost.
 
This article is originally posted on tronserve.com