The 5S System as an HSE Tool in a Small Enterprise

The development of a small manufacturing enterprise is inevitably associated with HSE challenges. During the active growth phase, when new employees are hired and equipment is purchased, safety issues often take a back seat to production tasks. However, it is during this period that the foundation of a safety culture is laid. In this webinar, Rinat Galimov, CEO of RIKA Group LLC, explains how integrating 5S principles allows not only for establishing order in the workshops but also for minimizing occupational injuries.

From Eliminating Micro-Injuries to Systemic Safety

At the start of the enterprise's operations, management faced typical problems: workplace clutter, a lack of cleaning habits among staff, and, as a result, regular micro-injuries. Using his production facility as an example, the speaker shows how targeted improvements change the overall safety picture. For instance, replacing a slippery staircase with a safe structure completely eliminated the risk of falling when climbing to the second floor, and introducing torque wrenches instead of makeshift tools when servicing extrusion lines prevented hand injuries when unscrewing bolts.

Special attention in the presentation is given to modernizing hazardous manual operations. Previously, the glue application process was done manually after heating it openly, leading to burns on hands and fingers. Purchasing a specialized line automated this process: glue is now applied inside a heat-shrink tube without direct worker contact with heated elements, completely eliminating thermal injuries in this area.

Workspace Visualization and Ergonomics

One of the key elements of 5S — visualization — is actively used to form safe habits. The speaker analyzes a case involving the use of hearing protection equipment. To overcome staff resistance, earplugs and earmuffs were placed directly in front of the start buttons for noisy equipment. This acts as an unavoidable visual trigger: a worker physically cannot turn on the machine without noticing the PPE.

The 5S system also solved the problem of cluttered aisles. Marking storage areas for finished products and work tools eliminated situations where parts were left lying on the floor, creating a tripping hazard. Every tool location on the workbench is outlined and labeled. This not only prevents heavy objects from falling at the assemblers' feet but also allows for instant visual identification of missing equipment, reducing search time and cutting costs for purchasing lost consumables.

Behavior Management and Discipline

The presentation details the approach to changing unsafe behavior. When employees started taking shortcuts under warehouse racks to save time, standard briefings and logbook signatures yielded no results. The problem was solved by physically blocking the dangerous route — installing equipment and warning tapes, making passage impossible.

A similar approach was applied to smoking in the workplace. Instead of just issuing bans, management equipped a comfortable smoking area while simultaneously introducing strict fines for smoking in the workshop. The combination of creating conditions and strict accountability completely eradicated the dangerous habit on the production line.

What you will learn from this webinar:

• How to organize tool storage using 5S tools and eliminate injuries from falling objects?
• What visual solutions compel workers to use PPE without constant supervision from a manager?
• How does physically blocking hazardous areas work more effectively than standard briefings?
• How does modernizing local processes (using hot melt glue as an example) eliminate micro-injury risks?
• How to use non-material motivation and collective selection of the best employee to maintain order in the workplace?