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The Benefits of “Sustained Discipline” (“Shitsuke”)

What are the benefits of Shitsuke in the 5S process?

Briefly: all the benefits from the first four steps would be lost without a deliberate effort to sustain the discipline of the 5S method.  In addition, the discipline in Shitsuke helps individuals and organizations when they tackle further initiatives.

In general, it takes time and repetition to form any new routine. People are likely to slip back into their previous habits. Regarding the 5S process, this means falling back into being messy or disorganized.

Routine deadlines and productivity quotas can also hinder the 5S processes, especially if management does not reward compliance. A worker who needs to stay just a bit late to complete a production assignment may not voluntarily store tools and clean up. Should that person be compensated for the extra time? Is every employee required to follow the Seiketsu (standardized cleanup) as part of regular work?

A more detailed list of the benefits of Shitsuke includes:

• Maintaining employee morale by:
• The sense of joint effort and pride of accomplishment would be lost if standards slip
• Morale would sink if employees begin to believe that management does not follow through on projects
• Sinking back into a messy workplace would undo the pride that comes with having a clean and well-organized environment
• Continuing to pay attention to employee suggestions
• Long-term productivity improvements due to:
• Reduced wear and tear on machinery, due to greater cleanliness and regular visual inspections
• Consistently storing tools in the proper places: the most frequently-used are nearest to hand; no need to play “hunt the hammer” since it is stored correctly
• Clear communication, especially on signs that show where tools are stored; what hazards to avoid; or what routes to take to avoid moving equipment
• Clear communication on bulletin boards and in libraries, since out-of-date materials are discarded or filed away
• Quicker to find needed tools or materials, since there is no useless clutter in the storage area
• Quicker to move materials around the shop, since there is no useless clutter on the shop floor
• The proper tools are more efficient than patched or improvised ones
• Higher quality with greater consistency because of clear work instructions
• Improved health and safety:
• Lower concentrations of airborne contaminants (dust)
• Tripping and electrical hazards were reduced or eliminated in the Seiri step
• Well-maintained equipment: guards in place; leaking seals or gaskets are noticed and replaced; visual inspections spot the beginnings of cracks or rust, and these problems are addressed promptly
• Fewer injuries due to repeated awkward motions, because Seiri reduced bending and twisting to retrieve low items
• Fewer injuries due to uncomfortable work positions, because Seiri adjusted seating and workbench heights

Without Shitsuke – sustained discipline – at the “end” of the 5S process, any benefits from the first four steps will gradually evaporate.

Oskar Olofsson, 2010