The second stage of 5S implementation program is 5S Seiton. 5S is considered as a more effective and efficient lean manufacturing methodology that is responsible for creating standardized working practices which can also improve housekeeping, and other extraordinary things. Aside from that, all of the clutters in your work place will be removed and the remaining items will be arranged chronologically in the cell.
People utilize or apply the 5S Seiton for the reason that, it has the capacity to find a particular place for all things in your working area. In this way, you need to bear in mind that everything should be placed closely for safety and for easy reach. In this step, you will be assured that your working place will be ergonomic. Meaning to say, the area will be arranged that is conducive to minimize movements and stress free environment. You will also be guaranteed of 100 % safety. The seven wastes will be eliminated as well.
When it comes to the implementation, there are various methodologies you can utilize. However, you need to take into considerations the size and the complexity of your working space. To give you an idea what to use, you can employ spaghetti diagrams in order for you to map out the whole process. It is a drawing of your work area wherein you draw a line to show movement. The spaghetti diagram appears as if you dropped a piece of spaghetti on the drawing and you have to work on removing and reducing the few pieces of spaghetti.
You can also employ a flow chart while utilizing post it notes. You can arrange these on a white board or a wall in order for the team to ascertain the non-value adding and value adding step. In this scenario, this can be considered an educational process for all individuals involved. In addition to that, you ought to work on reducing or eliminating all non-value adding step via placing things closer, arranging them in an easy manner that will support you in finding the position. Apart from that, you also have other choices like “go for it”. In this method, you can begin arranging things where you think the position you have is the most comfortable and convenient one.
Origin
Seiton originally came from Japanese where it was developed by Hiroyuki Hirano. The step has been found to be very effective and efficient in housekeeping as it has optimized manufacturing performance and best practice. As a methodology, it came from Toyota Production System, and Total Productive Maintenance that has the capacity to create efficient and ergonomic work places.
Examples
When you want to use and apply Seiton in housekeeping, working area, etc. there are examples that you can do such as putting a soap and hand towel that is close to the sink, taping instructional manual on a particular appliance, printing safety concerns and operating instruction on a specific machine, utilizing letter classifier, and more. Thus, this agile step, you can now arrange your place in order.

— Slimane Zouggari

Seiri is the first step of the 5S method, which means organizing or sorting out of the necessary equipment or even materials of both the required and non-required items. This is the identification of best physical organization of a certain workplace. Moreover, it is also a series of different steps, which help in identifying the things that are being held in workplace when they should not or the things that are being held in wrong place.
This has two major goals:
• To reduce the wastes
• To remove all the unnecessary objects
What are the objects are we talking about here? Why should we remove the objects that are not needed?
Well, in Seiri, the redundant objects might range from the empty boxes through the different bins of the rejected parts to the obsolete machinery in the workplace. Some of the objects may have some value but are inappropriate such as the jerry-rigged tools that mainly substitute for the proper equipment repair.
As you can observe, lots of workplaces are cluttered with the things that are no longer necessary. This does not apply inside a certain factory. There are offices that have libraries of the obsolete binders or manuals, or even filing cabinets that have outdated records that must be archived offsite.
Here are some of the good reasons for using Seiri:
• Sell the materials in order to realize the scrap value
• Free up the production space for your new business
• Free up the warehouse or office space in order to reduce the rental costs
• Save time when it comes to looking for a certain item that is needed the most
• Save time when it comes to making an inventory
• Save time when it comes to removing the goods mainly because there is a lesser clutter in your way
What does it really mean to reduce the waste?
Seiri mainly goes beyond just reducing the waste material through identifying all the hindrances while generating the ideas for the improvements.
How to sort the things out
It is the duty and responsibility of the management to commit employee’s effort and time such as making a plan and training. The steps mainly require teams. The smallest team must consist of representative line worker from production side, and maintenance technician. This will then provide well-rounded perspective right during the review. The supervisors must be included in the team. Always remember to involve the night shift personnel either as separate teams or even integrating them for the duration of the step.
Seiri is all about eliminating the unnecessary parts, instructions, and tools. It is always a must to have continuous education when it comes to maintaining the standards. If you are among those who are looking for the best way to make your workplace or office even more organized, trusting Lean 5S is definitely a wise move. You will surely be provided with proper knowledge on how to sort all the things in the workplace, thus resulting to handful of benefits since you will now have a workplace that is conducive for working.

— Slimane Zouggari

5S is considered one of the most powerful Manufacturing Lean tools and serves as a cornerstone of any types of successful implementation. This stands for Seiri, Seiton, Seiso, Seiketsu and Shitsuke which are simple tools that are specifically created for making your work place as organized as possible. It will also be cleaned, safe, and efficient that will be able to enhance the visual management, and productivity that will ensure the standardized of working in the company.
5S has a great emphasis on efficiency gains, and aesthetics in which you will be able to achieve by implementing the method. Apart from that, you should be aware with the methodology’s aim and that is the necessity to introduce the operational practices that are standardized to guarantee you of having safe, efficient, and repeatable working ways.
Aside from the standardized working that gives you a good and stable foundation that will boost improvement by implementing the Lean Tools, you will likewise have highly visual workplace. Furthermore, it is a process that should be employed by all people who only work in the area. So, the individuals who do not have the knowledge and do not belong to the group cannot utilize the tool.
Origin
5S as a tool comes from the Toyota Production System (TPS) and Total Productive Maintenance (TPM). Nevertheless, there are various individual components such as making efficient and ergonomic work places that are seen to be indebted their origin to individuals such as Frank Gilbreth for his Time and Motion Studies, and Taylor for his Scientific Management. Gilbreth showed that, when the ergonomics of bricklayers working methodologies are being improved, he would be able to lessen the number in individual movements that are required. The output in an hourly manner will be increased from 120 to 350 bricks.
Concept
5S is particularly a way that will help you organize your working practices and work place. In the Seiri, you will be supported in sorting, clearing, and classifying. In Seiton, you will straighten, set chronological order, and configure. In Seiso, you will sweep, clean, shine, scrub, and check. In terms of Seiketsu, you will standardize and stabilize. Lastly, when it comes to Shitsuke, you will be able to sustain self-discipline, practice, and custom. In order for you to attain completeness, there are other companies that make it 6S and that is for Safety. But, according to experts, it should be a crucial and salient part to the 5 Steps and not become a separate stage. So, all of these things are truly helpful and beneficial.
5S is definitely a good help when you need to organize your working places. It will be clean, efficient, and safe as well that will totally enhance the productivity and the visual management. Apart from that, the work of every person in the company will be standardized. Likewise, efficiency and aesthetics will be achieved. Therefore, when you need the said services, you can count on the 5S a lot. In addition to that, you will be able to see the difference when you apply the tool at the working place.

— Slimane Zouggari

Poka-yoke is a mistake proofing in Japanese terms. It is a device involved in lean manufacturing used to minimize errors on equipment operators. Its purpose is to identify mistakes and incorrect parts in a product being assembled. It helps in the elimination of defective products by correcting, preventing and detecting the occurrence of human errors. Dr. Shigeo Shingo, a well-known authority in efficiency and quality control in Japan, adopted Poka-yoke as a formalized mistake-proofing concept and later on, it became a part of Toyota’s system of production.
Japan manufacturing is very particular with the quality of their products. They have a Zero Defect Quality Control and Poka-yoke is one of its components. Most Japanese companies perform the Poka-yoke scheme. Dr. Shigeo Shingo knows the value of efficient quality control and regarded this system to be sorting defective items as well as improving the manufacturing process. Poka-yoke is an agile mistake-proof mechanism that is very beneficial to lean manufacturing. It differentiates defects from mistakes and it provides fast feedback on defects and workers can check the quality of their work.
Dr. Shigeo Shingo classified Poka-yoke into 3 types:
1. Contact Method
Contact Method is the type that identifies product defects through testing its physical attributes like shape, color, or size. This method is very useful on situations like infrequent production, rapid repetition or environmental problems.
Examples: Fixed Diameter Holes, Limit switches, Toggle switches UTP cables with RJ45, Screw, fueling area of cars, Ethernet cable plug, analog and discrete sensors, etc.
2. Fixed-Value Method
This method has the ability to alert operators whenever certain movements are not done on the repetitive processes in lean manufacturing. This method has a fixed design wherein there is a fixed number of parts.
Examples: Egg tray, airport luggage cart, shoe-size gauges, etc.
3. Motion-Step Method
This method is responsible for determining if the prescribed steps in the manufacturing process were followed. There must be correct sequence.
Example: The operator needs to step on a pedal every cycle of the assembly; sewing machine, wheelchair, etc.
The Poka-yoke device alerts operators if there will be a mistake happening or if it actually prevented the mistake from happening. Dr. Shingo stated that errors are unavoidable in manufacturing processes. The solution for this is the appropriate implementation of Poka-yokes which would have positive benefits like error elimination and quality improvement, improvement in the capacity of production, simplified housekeeping, safety, lower costs, increased production and flexibility and operators will have improved attitudes.
Poka-yoke is a very important aspect of lean manufacturing in terms of incurring zero defects because defects results to higher cost of production and the need to reworking or eliminating the manufactured product. Using Poka-yoke devices to mistake-proof is necessary so that defects may be reduced and prevent it from happening. With the elimination and reduction of defects, satisfaction levels of customers will increase. There will be quality processes and higher production, workers will be more effective, problems are solved immediately, waste elimination and continuous innovations which equals to first-time product quality.

— Slimane Zouggari

Muri means unreasonableness in Japanese. It is overburdening your machines and employees wherein you are placing them under unwanted stress because of demands, which are very often unreasonable and pointless. Muri is one of the three wastes in lean manufacturing—Muri, Mura and Muda. Muda is all about the 7 lean wastes, which are Overproduction, Inventory, Waiting, Motion, Transportation, Rework and Over Processing and Muri (Overburden) is one lean waste that creates most of the non-value adding phases of Muda.
Examples of Muri:
• Unclear instructions
• Unreliable processes
• Lack of correct equipment and tools
• Poor workplace location
• Work mismatch (working on process you did not train for)
• Fluctuating demand
• Poor maintenance/defective equipment
• Bad communication directions
It is evident in the examples given that Muri produces waste and a horde of problems in both service and manufacturing companies, which eventually lead to more complications, and wastes within processes. Lean practitioners sometimes fail to discuss these areas and rather concentrate on the improvement of the timetable taken to perform single steps in a certain process through moving things around. Afterwards, they will claim savings but the truth is that what they did just made the machine and the operators to do the work for no realistic benefits on the process at all. To avoid Muri, make sure that operators are working through the processes efficiently with low stress levels.
To Reduce Muri
There are a number of lean industrial tools that are designed specifically for the reduction of Muri in manufacturing processes. This has to be given focus and common sense should be applied because is not a stiff approach—it is all about doing what’s best for the customers and workers. Below are few lean tools that can help reduce Muri:
 Standardization
5S (or Seiso, Seiton, Seiketsu, Seiri and Shitsuke) which is a lean tool begins with standardization. Your manufacturing processes should be fully documented and all workers should be well trained and are fit to work so that they can give their best in doing their work easily. SOPs allow ease of communication in the workplace and things are done in the best way. The operators can have simple instructions using cameras or word processing sets to guarantee that all of them are engaged in the working process. SOPs need to cover every single aspect of work from machines through delivery and billing.
 Total Productive Maintenance (TPM)
This lean tool can help reduce waste like Muri when implemented well. Well-planned maintenance program that can be utilized in the workplace ensures that disruptions regarding equipment are minimized.
 Jidoka
Jidoka is also known as Autonomation. This lean tool lets you trust your machine’s output. It works like poka-yoke devices, which makes manufacturing process, empowered. It avoids waste because things are corrected easily.
There is a necessity to eliminate Muri because it adds and contributes a lot to Muda, which will result to low productivity. Inefficiencies and stress on workers and machines will cost too much money. Money and effort is better saved when Muri is removed or reduced. Minimal waste can benefit companies’ additional profit.

— Slimane Zouggari

Kata is referred to as the patterns that are practiced as fundamental movements in martial arts in Japan. It can also be referred as any routine or basic forms of behavior. These are patterns that can easily be recognized. With clear expectations and through it, problems will be able to instantly be identified. Kata is the basis of improvement, attainment and setting of standards. Kata is linked in two behaviors in lean management—the coaching kata and improvement kata.
Improvement Kata is the repetition of the four-step pattern that an organization adapts and continually improves. This continuous improvement is done by specific problem-solving procedure, and it is a plan, do, check, and an act routine. PDCA habit as they call it. The steps are:
1. Determining vision
2. Understanding current condition
3. Identify next target condition
4. Moving towards the target
Improvement Kata’s pattern is very essential in innovation, improvement and adaptation because it is specific and goal-oriented. The practice of it is purposely helping businesses so that they can meet challenges and achieve their endeavors. It aims to alter mental operating systems in order for human abilities to be more nurtured. The context of Improvement Kata in lean tools needs to be applied. The absence of it is going to stop improvement because it should be reinforced in the daily management, problem solving, events improvement, quality, and circles in the lean environment. This program creates continuous learning and improvement to organizations.
Coaching Kata is the repetitive routine in which lean leaders are able to teach Improvement Kata to all members or employees of the organization. They are called coaches who give procedural guidance to their learners and this will enable their learners to be more successful in surpassing their obstacles.
Toyota Production System (TPS) is integrating and observing Kata. As a matter of fact, there is a management book written by Mike Rother entitled Toyota Kata. The book has been focused in the explanation of Improvement Kata and the Coaching Kata, and these are the ways to make repetitive improvement procedures possible. Toyota Kata regarded management as a methodical pursuit of anticipated conditions through utilizing human competencies in an intensive way. Rother said that it has the aim of providing sustainable competitive advantage to the company. Furthermore, another of its benefits is that it is long term. Their organizations have mastered the effective routines in order to develop solutions. Toyota is utilizing this approach as a primary job of their leaders to achieve the goals that they ever wanted to be done.
The integration of Kata in TPS is a big leap of innovation to the car company. This is because they are very concerned about the lean manufacturing and the minimizing of waste in their production. They also included Kata in their improvement process because they know that it has done big changes in the behavior and thinking of their workers with constant practice. Their workers can derive confidence in working and they will eventually avoid waste.

— Slimane Zouggari

Jidoka is considered as the forgotten foundation of the Toyota Production system and the lean manufacturing yet is the principle to be the most important on lean that can able to help achieve the real excellence. Jidoka is all about the source quality, or a quality, which is built in; there are no business company can be able to survive without the product and services excellence and jidoka is a route through on which this excellence is achieved.
Where Jidoka Come From?
Jidoka started its life through Sakichi Toyoda’s invention in the year 1986 is a simple device able to stop the shuttle in the automatic loom is thread is broken. It simply means that it can stop the machine from not only the defects creation but it also make the operator alert to the problem. Well, that meant one operator can operate many looms rather than to stand and watch a single loom to see is something will go wrong to it. This kind of principle is known as autonomation or sometimes automation with the human touch.
The Jidoka Principles
Its principle can be may be broken down in the following simple steps:
1. Discovering the abnormality
2. STOP
3. Fixing the immediate issues
4. Investigating and correcting the root cause of the problem
These principles are not only coffins to be used in the machines in the autonomation; jidoka is also visible in most aspects of the lean manufacturing when examination to it takes place.
Examples of Jidoka
Here are the few examples of device used for autonomation that can be seen in manufacturing and in daily situation:
 Tension detector
 Sensor
 Proximity switch
 Sheet detector
 Presence sensing device
 Surge protector

Jidoka Problem Solving
There are various machineries being produced nowadays that have incorporated the autonomation ideals in the designs. In addition, with the technology today, it is very expensive while the incorporation of autonomation for the machines’ designs is very simple. We tend to fail not of recognizing the highlighted problems but in making an effort to take action to make the problems corrected and solve its root cause. It is necessary perhaps that we are not only giving our supervisory staff and operators a responsibility and authority to stop the production if they see a problem but we also need to train them in the most accurate problem solving tools that enable them to remove the problem root cause.
We also need to ensure action that documentation process is updated in order to incorporate the changes and we are able to communicate those existing changes across the similar processes and similar products to impart the earning to all. In the process of Jidoka, the primary action is it detects the abnormality, for autonomation, the machine is using a simple sensor to trace the problem and stop and highlight it to the operator or to the supervisory staff. For the line stops the operator to detect the abnormality and stop the line and to highlight the problem for everyone to see in the andon boar.

— Slimane Zouggari