5S in Six Sigma - SORT / SET/ SWEEP / STANDARDISE / SUSTAIN

 The terms "SORT, SET, SWEEP, STANDARDISE, SUSTAIN" are a variation of the 5S Methodology, a systematic approach to workplace organization that forms a foundation for Lean and continuous improvement.

Here's the information formatted as a table:

Term (English)	Original Japanese	Core Action
SORT	Seiri (整理)	Eliminate the unnecessary. Go through all items in a work area and remove everything that is not required for the current operation.
SET	Seiton (整頓)	Organize the necessary. Arrange the remaining essential items so they are easy to find, use, and return. (A place for everything, and everything in its place).
SWEEP	Seiso (清掃)	Clean and inspect. Thoroughly clean the work area and equipment. This cleaning process acts as an inspection to easily spot equipment damage, leaks, or other problems.
STANDARDISE	Seiketsu (清潔)	Make it a routine. Create documented standards, checklists, and visual controls to maintain the first three S's (Sort, Set, and Sweep) consistently.
SUSTAIN	Shitsuke (躾)	Make it a habit. Instill the discipline to follow the standards through training, self-control, and regular audits to ensure the 5S principles never lapse.

5s is the tool for :

• Improving the environment
• Raising morel
• Increasing workplace safety
• Increasing productivity and response time
• Impressing your customers
• Highlighting where to remove waste and non-value add activities

5S Methodology:

SORT -  Identify necessary items and remove unnecessary ones

SET/SIMPLIFY/STABLISE -  Locate items where they are needed and limit amount stored

SWEEP or SHINE = Visual sweep of all areas. Eliminate dirt, dust, and scrap. Make the workplace shine 

STANDARDISE -  Work to standards, wear safety equipment

SUSTAIN or SELF DISCIPLINE -  Make 5S strong in habit. Make problems visible and solve them

Successfully implementing and, more importantly, sustaining the 5S methodology requires more than just a one-time clean-up. It needs a cultural shift.

Here are essential tips for following each of your 5 S's:

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1. SORT (Seiri): Eliminate the Unnecessary

• Implement the Red Tag Strategy: Use red tags to mark any item that the team is unsure about or knows is unnecessary. Place all "red-tagged" items in a central "Holding Area" for a set period (e.g., 30 days). If no one needs the item after that time, discard, donate, or recycle it.

• Involve the Whole Team: The people who do the job know what they need and what they don't. Involve operators and staff directly in the sorting process to get true buy-in and accurate decisions.

• Take "Before" Photos: Document the starting condition of the area. This provides a clear contrast to show the team's success and motivates them for the next area.

2. SET (Seiton): Organize the Necessary

• "A Place for Everything, and Everything in its Place": This is the core principle. Use the rule of frequency:

  • Daily use items: Keep them within arm's reach.

  • Weekly use items: Store them in the immediate work area.

  • Seldom-used items: Store them away from the immediate work area.

• Use Visual Controls: Make it immediately obvious when an item is missing or out of place. Examples:

  • Shadow Boards: Pegboards with painted outlines of tools.

  • Floor Markings: Colored tape to outline workstations, storage areas, and walkways.

  • Labels: Clear, large labels on shelves, drawers, and bins.

3. SWEEP (Seiso / Shine): Clean and Inspect

• Cleaning is Inspection: The goal is not just a tidy area, but a workplace where abnormalities (leaks, cracks, loose bolts, equipment wear) are quickly noticed. When cleaning, employees should be actively inspecting.

• Find and Eliminate the Source of Dirt: Don't just clean up the oil spill; find out why the oil spilled (e.g., a loose fitting, a leaky hose) and fix the root cause. This prevents recurrence.

• Assign Clear Responsibilities: Establish a simple, daily cleaning routine (e.g., a "5-minute 5S" at the end of a shift) and clearly assign zones and tasks to specific individuals or teams.

4. STANDARDISE (Seiketsu): Make it Routine

• Document the New Normal: Create simple checklists, visual work instructions, or one-point lessons (OPLs) for the first three S's (Sort, Set, Sweep).

• Use Visual Standards: Standardisation means that any person can look at any work area and immediately know if it is operating "normally" or "abnormally." This includes:

  • Standard colors for floor markings (e.g., Yellow for walkways, Red for hazardous areas).

  • Standard label size, font, and placement.

• Integrate into Daily Work: The standards should be incorporated into the routine work cycle, not be seen as an add-on task.

5. SUSTAIN (Shitsuke): Make it a Habit

This is the most critical and difficult step—making 5S a permanent part of the culture.

• Leadership Commitment: Senior management must regularly participate in 5S audits and walks. When leaders show they care, everyone cares.

• Regular Audits and Scorecards: Implement a frequent (weekly/monthly) audit system using a simple checklist/scorecard. Post the scores publicly to create positive peer pressure and a friendly competition between teams.

• Training and Onboarding: Make 5S training mandatory for all new employees and a regular refresher for existing staff. It must be seen as fundamental job competence.

• Recognition and Celebration: Publicly recognize and reward teams or individuals who demonstrate excellent 5S practices. Celebrate improvements (e.g., a pizza party for the winning area) to keep momentum and enthusiasm high.

• Integrate into Performance: Tie 5S adherence and improvements into performance reviews or departmental goals.