Six Sigma is a process improvement methodology that is used in a variety of industries to improve efficiency and reduce costs. By using a set of tools, processes and practices, Six Sigma helps organizations achieve their objectives in a systematic and organized way. It is a highly effective and widely used approach in both manufacturing and service industries. The goal is to identify and eliminate waste, improve quality and reduce costs. There are five phases in the Six Sigma methodology: Define, Measure, Analyze, Improve and Control (DMAIC). The Define step is the first step in the process and it helps to identify the problem and identify the customer’s needs. The Measure step is used to collect data related to the problem and identify the key process variables that need to be monitored. The Analyze step is used to analyze the data and develop a cause and effect diagram or process map. The Improve step is used to develop and implement the solution and the Control step is used to monitor and control the process.
6S Methodology || 5S + Safety
Principles of the 6S method
Here are descriptions and illustrations of each of the 6S method’s ten principles:
Sort
The first principle of the 6S method is sorting. This step concentrates on clearing the workspace of clutter and streamlining organization to make it simpler for team members to locate the equipment and materials they require to work effectively. During the sorting process, managers and other leaders frequently employ the red and yellow tag system. With this system, unwanted items are marked with a red tag to indicate that they should be thrown away right away. Then, supervisors put yellow tags on items that the group can take temporarily off-site for use. Teams may find it simpler to maneuver through their workspace safely and effectively as a result.
Set in order
Set in order is the second rule of the 6S method. The group creates a strategy to move the tagged items, tools, and supplies in an orderly manner to the locations that make the most sense during this phase. Creating a methodical approach for organizing and retrieving items is the goal of this. By doing this, a company can make the most of its storage space and improve team accessibility in the future. To make it simple for any member of your team to find the tools and materials they require at a later time, make sure to record where you intend to store each tagged item.
Shine
The third principle of the 6S method is shine. Following the team’s off-site relocation of all non-essential materials, equipment, and work items, this step focuses on cleaning the workspace. Teams frequently carry out necessary upkeep and organize the remaining items during this phase. They might also conduct a thorough cleaning of the entire office. The shine phase of the 6S method seeks to establish a neat working environment that guards against accidents and keeps goods clean. Maintaining a clean workplace can boost productivity and employee morale.
Standardize
The fourth principle of the 6S method is standardize. In order to foster consistency, leadership establishes best practices and policies for the workplace during this phase. Teams can use this to establish more effective work routines and habits. Using visual cues, routine inspections, and clear expectations for team members, leaders can put these new practices and procedures into place. Standard operating procedures (SOPs) can facilitate your team’s progress toward its objectives.
Sustain
The fifth principle of the 6S method is sustain. This step aims to make sure a company adheres to the new policies and practices set forth by leadership by tracking their development over a predetermined period of time. The objective is for the organization’s members to naturally follow the established standard operating procedures after this time period. Leaders may establish key performance indicators (KPIs) to gauge the success of these adjustments and whether team members are adhering to protocol. Some KPIs you might consider using include:
Safety
Safety is the sixth and final tenet of the 6S method. To keep their team safe, leaders concentrate on identifying risks and creating preventative measures during this phase. Additionally, it’s critical to take this action to make sure the company complies with all regional and industry safety regulations. The 6S method’s emphasis on safety can help you reduce accidents and foster a more positive work environment.
What is the 6S method?
The 6S method is a system that seeks to advance and maintain high standards of productivity and security throughout an organization. This system expands on the 5S method, a manufacturing continuous improvement methodology that was developed in Japan. The Japanese words for sort, set, shine, standardize, and sustain are known as seiri, seiton, seiso, seiketsu, and shitsuke. All of these ideas are present in the 6S method along with the safety component. The following are some of the most popular industries that employ the 6S method:
Benefits of the 6S method
The 6S method is widely used in businesses to create better working environments for their staff, but there are many advantages as well. The 6S method has a number of advantages, some of which are listed below:
Reduced costs
Because the 6S method improves waste management by getting rid of unnecessary items, businesses that implement it may experience lower costs. The 6S methodology can also assist businesses in planning routine maintenance for equipment to lengthen its lifespan and reduce downtime. Last but not least, teams can use the 6S method to forecast the shelf life of products and materials, like chemicals or batteries, to make sure they use them as soon as possible. This results in more efficient investments, orders, and cost-saving procedures.
Increased efficiency
The 6S method can increase productivity for businesses by reducing distractions and enhancing focus. Team members can more easily find the tools and supplies they need by arranging their workspace using the 6S method. Lastly, by ensuring team members properly maintain the machinery and equipment, the 6S method can reduce downtime.
Improved production quality
Organizations reduce distractions by implementing the 6S method to create a secure and orderly workspace, which enables team members to concentrate on producing high-quality products. A lot of 6S method-using manufacturers also incorporate inspection software, which they can use to perform quality audits. This will enable them to assess their progress, establish benchmarks for quality improvement, and raise customer satisfaction.
Decreased stress levels
Leaders frequently create manuals, guides, and other documents for their team in order to implement new procedures for the 6S method. Team members may receive step-by-step workflows from this, which will facilitate and speed up their work. A standardized set of best practices can also reduce stress and enhance the onboarding process for new employees.
Improved teamwork capabilities
By making it simpler for team members to recognize the next step in a process and who else on their team might need assistance, the development of standardized procedures and workflows can improve teamwork. Additionally, it enables team members to better train one another on various tasks. Last but not least, it makes sure that everyone is pursuing the same objectives and using the same metrics to assess their progress.
Decreased accidents
The 6S method places a heavy emphasis on safety. Leaders can reduce accidents by establishing safety protocols and taking proactive measures to lower risk. Team members may feel safer as a result, which could enhance their mental health and result in a more satisfying work environment.
Tips for implementing the 6S method
Here are some pointers to assist you in bringing the 6S method into your company:
FAQ
What does the 6S stand for?
Sort, Set in Order (also known as Straighten or Stabilize), Shine (also known as Scrub or Sweep), Standardize, Sustain, Safety is a lean process improvement tool.
What is a 6S audit?
Implementing safety procedures such as near-miss reporting, incident reporting, risk assessments, and other safety management tools is ensured by using a 6S audit or 6S inspection checklist.
What is 6S of good housekeeping?
Sort (seiri), set in order (seiton), shine (seiso), standardize (seiketsu), sustain (shitsuke), and safety are the six pillars of the 6S system.
