5s implementation in garment industry case study

5S Methodology in Textile and Garment Industry

Mofizur Rahaman Akash Fabric Marketing, Unifill Composit Dyeing Mills Ltd. Email: [email protected]

What is 5S Methodology? 5S is a workplace organization method that uses a list of 5S sort, set in order, shine, standardize & sustain. The 5S methodology is a systematic approach that originated in Japan and has been widely adopted in manufacturing industries , including the textile and garment industry. The list describes how to organize a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new organizational system. The decision-making process usually comes from a dialogue about standardization, which builds understanding among employees of how they should do the work.

In some quarters, 5S has become 6S, the sixth element being safety (safe).

Sort: Sort is sorting through all items in a location and removing all unnecessary items from the location.

• Reduce time loss looking for an item by reducing the number of unnecessary items.
• Reduce the chance of distraction by unnecessary items.

Simplify inspection:

• Increase the amount of available, useful space.
• Increase safety by eliminating obstacles.

Implementation:

• Check all items in a location and evaluate whether or not their presence at the location is useful or necessary.
• Remove unnecessary items as soon as possible. Place those that cannot be removed immediately in a ‘red tag area’ so that they are easy to remove later on.
• Keep the working floor clear of materials except for those that are in use for production.

Set in order: Set in order is putting all necessary items in the optimal place for fulfilling their function in the workplace.

• Make the workflow smooth and easy.
• Arrange work stations in such a way that all tooling/equipment is in close proximity, in an easy to reach spot and in a logical order adapted to the work performed. Place components according to their uses, with the frequently used components being nearest to the workplace.
• Arrange all necessary items so that they can be easily selected for use. Make it easy to find and pick up necessary items.
• Assign fixed locations for items. Use clear labels, marks or hints so that items are easy to return to the correct location and so that it is easy to spot missing items.

Shine: Shine is sweeping or cleaning and inspecting the workplace, tools and machinery on a regular basis.

• Improves the garment production process efficiency and safety, reduces waste, prevents errors and defects.
• Keep the workplace safe and easy to work in.
• Keep the workplace clean and pleasing to work in.
• When in place, anyone not familiar to the environment must be able to detect any problems within 15 metres (50 ft) in 5 seconds.
• Clean the workplace and equipment on a daily basis, or at another appropriate (high frequency) cleaning interval.
• Inspect the workplace and equipment while cleaning.

Standardize: Standardize is to standardize the processes used to sort, order and clean the workplace.

• Establish procedures and schedules to ensure the repetition of the first three ‘S’ practices.
• Develop a work structure that will support the new practices and make it part of the daily routine.
• Ensure everyone knows their responsibilities of performing the sorting, organizing and cleaning.
• Use photos and visual controls to help keep everything as it should be.
• Review the status of 5S implementation regularly using audit checklists.

Sustain / self-discipline Sustain is the developed processes by self-discipline of the workers. Also translates as “do without being told”.

• Ensure that the 5S approach is followed.
• Organize training sessions.
• Perform regular audits to ensure that all defined standards are being implemented and followed.
• Implement improvements whenever possible. Worker inputs can be very valuable for identifying improvements.

Conclusion: In textile & garment industry, 5S methodology can help improve efficiency, reduce waste, and improve quality by creating a more organized and standardized workplace. By eliminating unnecessary items, organizing workstations and tools, and establishing standard procedures, the 5S methodology can help companies reduce costs, increase productivity, and improve customer satisfaction.

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Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.

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Textile and Finance

Implementation of 5S in Apparel Industry

5S comes from 5 Japanese words and each of them starts with S. These are seiri ,  seiton ,  seiso ,  seiketsu , and  shitsuke , if we translate these 5 Japanese words into English then we get Sort , Set in Order , Shine , Standardize , and Sustain . In the garment industry 5S works as a basic tool of Lean Manufacturing, a technique to set a well organized, clean, and visually attractive workplace. That’s why the implementation of 5S in the Apparel Industry is required.

Implementing the 5’S method is a base to implement quality improvement/lean procedures. Expecting the team to be and they do activities in each department: like monitoring, evaluate and drive the aspects very clean and organized so that, your Factory will look very planned and well Set-up.

Let’s have a look at the difference in English and Japanese words for 5S

Basic  Concepts for 5S Implementation in Apparel

S1. sort (seiri).

5S start with sort. Sort means to sort out unnecessary items, use all machines, tools, equipment for regular use. Define daily needed items, weekly needed items, and monthly needed items and keeping separate. The store is broken, unusable or occasionally used items also should be defined. Keep records for eliminating unnecessary items that exist and new items. Each and every section of garments you may find many things are kept in a haphazard way. So for these, you need to follow the first S from the 5S, i.e Sort. Sorting according to items characteristics and importance.

S2 – Set in Order – SEITON

Setting order is important for 5S. All items, sections, and areas (In, exist) are clearly identified by a label and everything should be well organized. Never mix/store two category items in one place. Dividing lines, aisle mark, Stairway is clearly identified and clean as per standard. Confirm that the exits are accessible and unlocked during working hours. Confirm that, where necessary, the emergency exit doors have no panic hardware or lever style (one hand, one motion door openers). If you keep all of your store materials in your garments warehouse in a planned order basis, then whenever required that materials you can easily find out and get those materials. That’s why all materials should be kept in accordance with the set in order.

S3 – Shining – SEISO

The third S from 5S is Shine, actually mean cleanliness. All items/place of workplace Floors, walls, stairs, ceilings, pipework Racks, cabinets, shelves, Machines, equipment, tools, Stored items, materials, products, and lighting everything required to be kept clean. All cleaning tools and materials are easily accessible. Cleaning assignments are defined and are being followed by the checklist and hang checklist on visible board. Do periodical pest control to make sure there is no insect. Cleanliness is not only a compliance issue but also this increase a healthy working environment in garments factories or offices.

Download:  S3: Shine, Cleaning Schedule (Excel 20kb)

S4 – Standardize – SEIKETSU

The first three steps of 5S are the key to implement 5S in the workplace. This section is about visualization by Information displays, related SOPs, signs, color coding and other markings are established everywhere of the factory also included procedures for maintaining the first three S’s are being displayed. Do regular 5’s audit using a checklist, give & post rating to each area. Need formal training, keep training records to approach towards improvement. These standardizations increase the operating efficiency of the apparel industry.

S5 – Sustain – SHITSUKE

This section is to sustain 5S in the textile and garments factory to be the way of life rather than just a routine. Success stories are being displayed (i.e. before and after pictures) in every section of the 5S board. Give rewards and recognition is part of the 5S system to sustain 5S.

S6 and S7(Extension of 5S)

Now, 5S have two additional points 6th “S” for “Safety” and the 7 th “S’’ is “Security”. These two new points’ objective is to make a safe workplace for all employees. It is the employer’s responsibility to provide safety and security for both factory and office place in the apparel industry.

Advantages of 5S for Garments

If you properly follow 5S for your textile and garments industry, then you will get the following benefits:

• Health and Safety is ensured
• The base of implementation of quality improvement
• Productivity Increase
• Save time, cost and storage space
• Minimization of accidents & mistakes
• Increases efficiency
• Creates workplace ownership
• The first step for Lean procedures
• Increase customer satisfaction
• Reduce inventory time
• Reduce downtime, wastage
• Good working environment
• Visualization and labeling
• Boost morale
• Improve company image
• Optimize organization and workplace as per requirement
• Routine wise work schedule and visual Standard Operating Procedure (SOP) everywhere
• Everybody knows their working responsibility where and when
• Disciplined housekeeping

For implementing 5S in Apparel Industry you need to follow the followings:

• Need central 5S committee and section-wise subcommittee
• 5S organogram and committee list as enclosed
• Section-wise 5S checklist
• 5S display board in every section
• Make a separate T-shirt for a committee
• Conduct 5s training and drive for good housekeeping
• Conduct a section-wise 5S audit and submit a report.
• Evaluate score and take corrective action for improvement in every department.

Actions Need to Implement 5S in Garments Industry

• Take “before” photographs.
• Check that the first three S’s are implemented properly.
• All team activity documents/checklists should be publicly displayed on a 5S board.
• Establish the routines and standard practices for regularly and systematically repeating the first three S’s.
• Standardize red tag procedures and holding area rules (see Seiri).
• Create a maintenance system for housekeeping. Make a schedule for cleaning the workplace. A common approach is to ask a cross-functional team to do it.
• Inter-departmental competition is an effective means of sustaining and enhancing interest in 5S.
• Assign responsibility to individuals for a work area and machinery.
• Regular inspection/audit and evaluation by a special team (including senior management persons) to be continued.
• Instead of criticizing poor cases, praise and commend good practices or good performers.
• Take “after” photographs and post them on the 5S board(s).
• Give a reward for the top-scoring section.

You can download Presentation File on 5S if you need it.

5S Presentation: PowerPoint (6.3MB)

5S Training: PowerPoint (5.1MB)

5S Presentation (English & Bangla): PowerPoint (6.9MB)

6 thoughts on “ Implementation of 5S in Apparel Industry ”

MaasyaAllah, thank you very much Pak Washim for sharing this knowledge. It helps me a lot.

Jazakallahu khoiron. Barakallahu fik.

5S is an integral facet of manufacturing excellence. Though early resistance may be felt, the benefits will soon become apparent. Visual Management is absolutely key. Great article.

Thanks a lot for your idea sharing with us. It is great post!

It’s a great idea for me thanks for published it .

Thanks for sharing your info. I was able to find good information from your blog post

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A critical review on implementation of 5S and six sigma in textile industry

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Jesica Roshima Alexander , A. Vasudeva Reddy , N. Konda Reddy; A critical review on implementation of 5S and six sigma in textile industry. AIP Conf. Proc. 8 September 2023; 2800 (1): 020280. https://doi.org/10.1063/5.0163127

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The purpose of this paper is to review quality management literature comprising of Lean management, Six Sigma in textile industry. This paper highlights the implementation of quality management practices and improvement in the productivity through extensive literature review. The literature survey has confirmed that a clear dependency upon the commitment of top management and leaders of the business unit through support and optimized resource allocation for reducing waste, thereby improving quality, reducing cost of production and ultimately increasing customer satisfaction. Implementing TQM across is a process with a number of iterations before tasting the fruit of success. It is an approach, focusing on detailed formulation of strategies undertaken towards successful organizational improvement through enhanced innovation. This paper provides a mode of viewing quality through excellence model along with lean and six sigma principles with customer as the primary focus for the business.

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Lean Supply Chain Management in Fashion and Textile Industry pp 269–290 Cite as

Lean Manufacturing: Case Studies from Fashion and Textile Industries

• Majo George 3 ,
• Nguyen Minh Ngoc 3 ,
• Le Khac Yen Nhi 3 ,
• Vuong Nguyen Dang Tung 3 ,
• Le Phan Thanh Truc 3 &
• Rajkishore Nayak 4  
• First Online: 30 August 2022

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Part of the book series: Textile Science and Clothing Technology ((TSCT))

This chapter will focus on various case studies relating to the failure and success of various industries in the fashion and textile manufacturing sector. From the earlier chapters (Chaps. “Lean Manufacturing: Case Studies from Fashion and Textile Industries” – “Digital Technologies for Lean Manufacturing” , it has been clearly mentioned that the implementation of various lean tools such as Kaizen, Muda, 5S and Kanban can help the traditional industries to improve their productivity and efficiency by reducing waste. This chapter will discuss the implementation of lean manufacturing by some of the fashion and textile industries and its impact on productivity and efficiency. The chapter has been divided into three sections for better flow and understanding. The first section will discuss some case studies focusing on the failure of some of the industries from Africa and India due to not implementing of lean manufacturing tools. The second section will focus on the case studies focusing on the success of some of the fashion and textile industries by adopting lean manufacturing tools. Finally, the third and last section will focus on the future directions and conclusions of this chapter.

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George, M., Ngoc, N.M., Nhi, L.K.Y., Tung, V.N.D., Truc, L.P.T., Nayak, R. (2022). Lean Manufacturing: Case Studies from Fashion and Textile Industries. In: Nayak, R. (eds) Lean Supply Chain Management in Fashion and Textile Industry. Textile Science and Clothing Technology. Springer, Singapore. https://doi.org/10.1007/978-981-19-2108-7_11

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