Integrating 5 S principles with process improvement: A Case Study

Abstract

Abstract--Lean manufacturing may be applied predominantly in the manufacturing environment, however it is aptly applicable to the service industry as well. 5S may be considered as a tool of lean as it reduces waste and adds value to the process. It may be combined with other tools such as Kanban, Kaizen, total preventive maintenance, total quality management in addressing pertinent issues in the workplace. Thus managers’ face increased pressure to improve performance within their organisations. Performance management is the “buzzword,” including national and international competition. In order to accomplish this objective with a decreasing workforce, managers are empowering employees to take responsibility on productivity and performance. By creating a workplace that is conducive to achieve this performance, in consideration of health and safety, work design and productivity, the implementation of the 5-S principles can become one of the sustainable competitive advantages in industry. The objective of the study is to highlight that many organisations, both manufacturing and service, lose millions of rands in the form of waste on a regular basis. Therefore integrating these principles into a plant’s culture can cut worker’s compensation costs, reduce lost time, improve productivity and quality and strengthen labour-management relations. The objective of this paper is to highlight that 5S principles are fundamental to the workplace and to indicate that the monetary value of waste across the spectrum is insurmountable. In order to achieve this, a case study methodology was used as it was the most applicable method of collecting data. The best way to make the 5-S principles an integral part of plant culture is to develop a plant-wide programme. The study provides an overview of workplace challenges experienced. It is the researcher’s intention to emphasize the importance of these basic principles and its associated benefits for all stakeholders through an exploratory research design.