The motto for step 2 of the 5S approach (i.e., set in order) is:
“A place for everything, and everything in its place”
Before you start reading this article, be sure to brush up on the first step of the 5S approach – to ‘sort’.
Things to keep in mind about Step 2 (Set in Order):
- To ‘set in order’ is about how to keep the needed items in an organized way.
- The leading cause of an unorganized workplace is not putting objects back in their place. Therefore, we can sum this habit up by the phrase ‘we are what we do consistently’.
- Good visual signs are needed to promote putting objects back to their respective place after use. For instance, let us take the case of a whiteboard marker-holder placed near the whiteboard. With visual signage like “whiteboard markers”, the first step in the direction towards setting order can be achieved.
Similarly, to set in order, every object needs a location. These locations need a visual sign. Hence, if these two are available, a habit is bound to change over time. It is a journey.
Steps to Set in Order:
Crucial Component to ‘Set in Order’- Spaghetti Diagrams:
Spaghetti diagrams are useful in the step ‘set in order’. They are a map of the path taken by a specific product as it travels down the value stream in a mass production organization. It is called a ‘spaghetti’ diagram because the product’s route typically looks like a plate of spaghetti! Most importantly, spaghetti diagrams help identify flaws in a given layout. Using a spaghetti diagram, you can create a layout with a better flow by identifying and removing unnecessary transport. Therefore, it is beneficial to carry out a spaghetti exercise during this step.
Steps involved to make a spaghetti diagram are:
- Identify the product (usually the most produced) in the line. If you are working in the service industry, trace the person if movement between workstations is involved. Contrastingly, if you are working in the IT industry, this tool isn’t required.
- Trace the product flow as manufacturing takes place.
- Map the flow on a layout (can be a handwritten drawing).
- Brainstorm changes as necessary. Soon after, freeze on these changes.
Here’s an example of a spaghetti diagram:
Figure 1 – A spaghetti diagram
Set In Order: Various Activities
Actions during step 2 of 5S include the following:
- Mark aisles
- Apply labels and other visual signs to find the objects
- Make suitable storage systems for the items in scope
- Decision on the quantity of storage and changes to the layout
Set In Order: Supplies Required
Supplies needed for Step 2 of 5S include:
- Yellow tapes
- Label printing machines
- Shadow boards
While you implement the ‘set in order’ step, it may take you some time to get ‘perfect’ solutions. Don’t worry! Start with ‘imperfect solutions’. Stick with these until ‘perfect solutions’ fall in place! Moreover, make it a team activity. Hence, make everyone contribute, reward, and recognize innovative ideas. Make shop floor personnel own the initiative. This is the only way to sustain a 5S initiative.
Implementation of step 2 of 5S
The next step of the 5S approach is to ‘shine’.