5S - Accident Prevention System: The "Standardization" Step

Where does safety begin? There is probably no single answer to this question, but it is certain that an indisputable and vital factor in ensuring safety is order in the workplace. It's simple and straightforward. And I would say it's not just about order, but about the ergonomic arrangement of equipment and tools to reduce risks and labor intensity, organize effective work, and increase productivity.

To ensure order in the workplace, you can apply the widely used lean manufacturing system — 5S, which involves 5 steps:

1. Sort – clearly separating necessary items from unnecessary ones and getting rid of the latter
2. Set in Order – the orderly and precise arrangement and storage of necessary items, allowing them to be found and used quickly and easily;
3. Shine – keeping the workplace clean and tidy
4. Standardize – a necessary condition for following the first 3 rules;
5. Sustain (Self-discipline) – developing the habit of strictly following rules, procedures, and technological operations

Today, I would like to talk about the 4th step of this system, as it is quite extensive, and it is impossible to briefly cover practical tips for each step in a single post.

To "standardize" the correct placement of materials and equipment in our plant's production units, we successfully use site map diagrams that show:

• Locations of finished products, main equipment, workstations, packaging material storage areas, equipment charging points, etc.
• Main rooms/areas within the site
• Information boards
• Location of fire extinguishers and fire hydrants, safety showers (if available)
• Parking areas for loading equipment (forklifts and stackers)
• Pedestrian zones
• Main risks, PPE requirements for the area, first aid kits;
• Emergency contact number

Site maps are developed by the site manager together with the employees working in that area and are approved by the HSE department. In the HSE instructions for personnel, we specify the need to comply with the material layout according to the developed maps. Once developed, they are posted in the areas and on entrance doors so that a new employee or a guest moving from one area to another can familiarize themselves with the main risks and requirements of the site. Having this site map makes it convenient to conduct inspections (audits) and compare the standard with reality.

According to statistics at our plant over the past year, violations of 5S requirements are the most frequent among all types of violations. We have reduced so-called "physical risks" (such as lack of guarding, electrical non-compliance, etc.), but maintaining order remains a key focus for us.

To reduce risks and improve safety culture and behavior, we organized 5S audits based on a developed checklist, which helps encourage employees to comply with these requirements.

To assist with the system implementation, I am attaching an example of a site map and a 5S audit checklist, which can serve as a basis for developing your own 5S procedure.

[attachment=656:5s-chek-list-dlja-proizvodstva.xlsx] [attachment=657:2024-karta-5s-i-bezopasnosti-uchastka-upakovki.xlsx]