MONTHLY CHALLENGE
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One common Lean tool to making changes and taking action is a simple, but effective process called 5S. It is effective because
it provides a plan to accomplishing something that is visual to everyone. In most cases, it also creates immediate efficiencies
and improvements.
5S can take place in the maintenance bay, the design office, or through the computer files — and will help in shaping the
culture of your company to move from just talking about changes to making them. The following is a brief description of 5S
methodology:
1 Sort: Select an area, then begin to systematically evaluate what should be in that area and what should not be. It might mean you
need to go through the "painful" experience of throwing away that old transmission you bought at an auction 12 years ago that
your maintenance crew has to step over every time they need to get the backpack blower hanging behind it on the wall. After
all, when in doubt, throw it out!
2 Shine: Get out the mops, buckets, cleaning utensils and go to work. Clean everything in the area in which you are focusing. Don't
just dust; how about some new paint on the walls and the floor? Spray off the tools and equipment that will be stored in this
area. Be careful not to try and clean the entire world, just stay focused on the area you have selected. 3 Set in order: When you are ready to put back only the things that belong in that area, first add some shelves, hooks or designated space
on the floor to park equipment. Give thought to what should be placed where, based on making it efficient to locate and easy
to access.
Let me offer a quick note here for all of us who have instinctively used the first three steps described above only to find
that in time, the area in which we put all that effort eventually returned back to the way it used to be. This process has
more to it than just cleaning; it must become a mindset that shapes the culture of your company. That is why the next two
steps are essential.
4 Standardize: The easiest way to accomplish this is through labeling and creating some structure to the area of your focus. When a designated
label clearly reads "rake," it becomes more difficult to place the shovel there. Show faith in your team or yourself as a
leader. Try it, and your team will amaze you.
5 Sustain: This step is what separates your efforts from "just cleaning something" to an evolving culture of efficiency and Working
Smarter. Keep in mind that the project is not completed until you have put up some visual reminders and tracking that will
maintain and continue to improve what you have accomplished in this area. Post a simple map that shows where everything is
to be stored, and use an auditing system that consistently measures and evaluates how well everyone is adhering to the new
standard that has been established.
Making changes, even simple ones, often can be uncomfortable, seemingly time-consuming and can challenge the current state
of your company. Yet on the other side of the change, success is waiting patiently. What if a mind shift and a great 5S project
could help your company add 10% more billable hours in 2009, or add 3% improvement to client retention? When the correlation
between making changes and noticeable and measurable improvements is realized, a culture shift to continuous improvement takes
place.
More than 250 Green Industry companies have participated in JP Horizons' Working Smarter Training Challenge (WSTC), typically
saving tens of thousands of dollars annually. To see if your organization qualifies to participate in the WSTC, visit http://www.jphorizons.com/ today.
Jim Paluch is president of JP Horizons Inc. Visit http://www.jphorizons.com/.
