The application of 6S methodology as a lean improvement tool in an ink manufacturing company

Abstract

The lean 6S methodology, which comprises of 5S + safety, is a powerful and effective lean improvement tool which can be applied to any type or size of organisation. The traditional 5S was expanded to 6S in order to incorporate the concept of safety awareness in the organisation. It can be adapted to all processes within any organisation or industry. The 6S pillars are; sort, set in order, shine, standardize, sustain and safety. The purpose of this paper is to explore the application of the 6S methodology as a lean tool, in order to reduce waste, improve quality, increase productivity and enhance organisational performance. Two data collection methods were used to ensure the proper implementation of the lean 6S methodology. Within the framework of this case study, a 6S audit was conducted over a 8 week period and the audit score showed an increase from a score of 50 in week one to 90 in week 8, and organisational photography was utilised as a research tool to indicate the before and after application of lean 6S. By ensuing the 6S methodology, a significant improvement in safety, productivity, job satisfaction, quality initiatives, efficiency and housekeeping, can be achieved.