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Safety is a key component of the other Ss
The implementation of safety can help improve productivity and eliminate waste in many ways
The implementation of safety can help improve productivity and eliminate waste in many ways
Safety should be a key component of each of the other S's; however, some people like the idea of calling it the "6th S". Safety is one of the most important factors in reducing waste and improving productivity. Here are some of the ways safety can help eliminate waste and improve productivity within any workplace:
- Accidents Waste Time – When there is an accident in a facility, it is typically necessary to halt work while it is investigated. Depending on the severity of the accident, this can cause a work stoppage for hours or even days. Obviously this is very inefficient. Improving safety will reduce the number of accidents, which will then improve productivity.
- Injuries Slow Work – When someone is injured at work, they will likely have to take some time off to recover. It may be necessary to bring someone new into the facility, which will cost time and money. In addition, any workers' compensation that needs to be paid out could be considered wasted money also. Even once the employee returns, he or she may never be as efficient again due to the lasting effects of the injury.
- Safety Improves Organization – Many safety improvements can help a facility stay more organized, which improves efficiency. For example, if floor marking tape is used to divide up aisles into driving and walking paths, everyone will know where they need to be. This may allow people to travel faster, which in turn improves productivity.
- Employee Confidence – Employees who work in a hazardous environment are more likely to do things slowly to help protect themselves. When employees feel confident that the facility is a safe place to work, they can move at a faster pace and get the work done properly and in a timely manner.
- OSHA Inspections – If a work facility is found to be unsafe by OSHA, that facility is much more likely to have repeat inspections from the agency in the future. OSHA inspections, while important, do cause lapses in productivity. If safety can be improved, it is more likely to receive positive results from any inspections that do occur.
| 5S Title | Improvement Title | Safety Impact |
|---|---|---|
| Sort | Keep tool benches clean using foam inserts | Tools will be kept in better condition and will therefore be safer. Also reduces the risk of accidental cuts when searching for tools. |
| Set in Order | Organize warehouse shelving using labels | Being able to find items in the warehouse quickly will reduce the risk of items falling or someone being injured while searching through multiple areas. |
| Shine | Perform preventative maintenance on machines | Keeping machines in proper working order will help ensure they do not malfunction and cause an injury. |
| Standardize | Ensure employees across shifts are performing tasks the same way | Prevent accidents when employees are working on other shifts since everyone will be used to doing things the same way |
| Sustain | Analyze 5S improvements from previous quarter to ensure implementation is effective | Ensuring improvements were properly rolled out will help keep all the safety benefits in place long into the future |
Some other things you can do
- Make sure your employees have the correct equipment for their jobs. Hardhats, coveralls, gloves, and steel toe shoes are some typical items required in a warehouse or manufacturing complex.
- Train your staff to use the equipment correctly. Heavy equipment, electronics, forklifts, and power tools are all dangerous to those who use them incorrectly.
- Easy-to-understand labels, signs, and other markings contribute to creating a safe, visual workplace.
- Train your staff on exactly what to do in an emergency. From small incidents like cuts and bruises to larger ones like injuries and fire, each employee should know what they need to do or who they need to notify.
References:
- Pojasek RB. Five S's: A tool that preparres an organization for change. Environmental Quality Management (Autumn 1999) pp.97-103. www.epa.gov/lean/
- Creative Safety Supply 5S Training and Research Page. www.creativesafetysupply.com/content/education-research/
- Creative Safety Supply 5S Guide. www.ksre.k-state.edu/agsafe/announcements/
- Ministry of Health, Lilongwe, Malawi. Health care quality improvement manual for in-service training. February 2019 (Final Draft)