5S

5S is a Japanese technique for keeping the workplace in order, clean and deploy a self-discipline routine. Properly implemented 5S method can establish a visual control system in the workplace which will be vital to tackle the 8 wastes of lean. The aim of this paper is to implement 5S in a pharmaceutical factory and compare the results of before and after implementation. The following departments were chosen for the implementation project: Admin, Production (a particular section), Store and Quality Control. Before starting the implementation process, the current condition of these departments were recorded. For collecting the data, observation charts, previous audit reports and photographs were used. Relevant training in 5S was given to all the employees before the implementation phase. The target was to attach and involve everyone with the development process. During the implementation phase, the steps of 5S were followed accordingly: sort, set in order, shine, standardize and sustain. The areas that were part of this project were monitored and kept in observation for two months. In this observation period, new set of data were collected to justify the change. New observation sheets were prepared and new photographs were taken. The before and after implementation data were compared. The result showed significant reduction of cycle time in the areas where 5S were implemented. As the result was positive and satisfactory, some set of standard was set so that everyone in the factory will follow the same procedure. For sustaining this improvement, the factory was divided into several zones at the beginning. During the study period, the groups in the selected zones were audited and they received scores according to their performance. As the 5S implementation showed satisfactory positive results, top management decided to implement this throughout the factory. Each zone has a 5S committee consisting of a team leader and some group members. Their responsibilities are to implement the standardized format of 5S that was prepared for this factory regularly after the observation period. Continuous monitoring and regular 5S audit will help to sustain this technique at this factory.