It is well known that most companies struggle sustaining 5S. The last S stands for sustain in 5S is the hardest of all because it requires discipline and commitment to sustain 5S.
I always hear people complaining about how difficult it is to discipline their work force.
This company I visited few months ago was using 5S for years and was able to sustain it. Their plant floor was clean, full of light and equipment was within the markings on the floor, tools in their place and product flowing smoothly.
I discovered their secret to sustaining 5S by observing their process.
The layout of this plant was such that production was on the first floor and offices on the second floor.
Operators had 15 minutes to clean up their station before leaving for the day. Just before the end of every shift, the line leaders would go the second floor to observe the operators working on the first floor. They were specifically observing whether operators were following 5S that involved cleaning the station, removing unwanted material/product, putting tools in their respective places.
This simple action ensured that operators followed 5S everyday. Using the power of observation, this company was able to sustain 5S.
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