The Top 5 Questions on 5S in the Food Industry

In the webinar “5S in the Food Industry: How to Develop an Employee-Driven Tool Management Program,” Amit M. Kheradia shared insights on how 5S can transform workspaces into clean, safe, and well-organized environments by focusing on hygiene, sanitation, and material handling tools. With over 1,800 participants, there were many great questions that couldn’t be addressed during the session. Here are the top five answers from Remco and Vikan hygiene experts.

1. How is 5S related to Lean Enterprise, and can it help eliminate waste in a food facility?

5S originated in Japan's automotive industry and became a key component of Lean Enterprise, which aims to reduce or eliminate waste—often referred to as TIMWOODS (Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, Skills). While not all wastes can be fully eliminated, implementing 5S can significantly reduce issues like rework, cross-contamination, and inefficiencies by maintaining a structured, clean environment.

2. What’s the difference between zoning by 5S and color-coding, and how do shadow boards support 5S?

5S zoning divides the workspace into specific areas with assigned responsibilities, while color-coding helps identify tools for different zones (e.g., red for food contact, blue for ready-to-eat areas). Shadow boards, which show where each tool should be placed, make it easy for workers to find and return tools, supporting visual management and reducing errors.

3. How can you motivate employees to adopt and sustain a 5S program?

Getting buy-in from both management and frontline staff is crucial. Creating a 'visual factory' allows problems to be seen and fixed quickly. Breaking tasks into simple steps, providing training, and involving teams in root cause analysis can boost engagement and ensure long-term success.

4. Can 5S replace GMPs, and does it improve employee safety?

No, 5S doesn't replace Good Manufacturing Practices (GMPs) but supports them by making visual issues easier to spot and fix. It also enhances safety by reducing clutter and improving visibility, which lowers the risk of accidents.

5. How can you sustain a 5S program over time?

Sustaining 5S requires building a culture of continuous improvement. This includes regular reviews, using visual communication, and ensuring that reviewers are separate from implementers. Empowered employees who understand the system are key to long-term success.

Our Remco/Vikan Site Survey can help your team establish an effective 5S tool management system. Contact us for a virtual or on-site consultation to address your unique challenges. Let us know if you'd like more details!