You decided to implement 5S at your workstation. You sorted all the materials and tools, keeping only what was necessary and removing the unnecessary items. Everything that is necessary has been set in order and given a place. You cleaned and shined, making the workstation sparkle. Your work instructions are used to standardize the process. It looks great, and working is easier until the little things start reverting. Before you know it, the workstation is back to chaos. Extra tools, extra parts, and scraps of materials are strewn all over the place, and to top it off, the work instructions are missing… again.

Usually, the fifth S, Sustain, is the biggest casualty in the work area, especially if the work environment is comprised of experienced workers with a set way to perform their function. It can be difficult to break those old habits. I can’t tell you how many times I’ve searched for a 10mm socket after I put it down on my workbench instead of in the socket tray. So, how do we sustain the changes made through the 5S process?

I like to start with visual management. After I’ve sorted, set in order, and shined, I take a picture of the workstation and create a laminated poster with everything labeled. I use shadow boards to hold the necessary tools for the workstation. For some, getting used to a shadow board can be difficult. I am used to setting my tools down to grab the next one; however, having to take a tool from the board reminds me to hang up the tool that is in my hand. Before long, the worker gets used to putting the tool back where it belongs.

There is a lot of talk about training the workers on 5S and the new procedures. I like to get the person doing the job to provide input on the design of the shadow board and the location of the materials used. The tool they use the most should be front and center, closest to the work. Engagement of the worker ensures that the new workstation will stay that way.

Making regular visits to the work areas (Gemba Walks) to observe practices and talk with the workers helps identify potential issues, many of which can be corrected instantly. Empower the workers to continuously improve by actively looking for ways to further refine 5S practices.

Regularly communicate the importance of 5S. I’ve seen 5S posters hanging on the wall. It works for a day or two, then it becomes wallpaper and is ignored. Highlight weekly or monthly success stories to maintain employee engagement.

Although Sustain is only one of the five principles of the 5S methodology, it encompasses 90% of the work. How are you managing your workstations? Do they need some improvement? I would love to hear your 5S story. What are you doing to Sustain? Let me know in the comments.