What Is Lean Safety?
Smart companies know that enhanced organizational safety leads to increased efficiency, cost savings, and a better brand reputation. Have you considered lean safety to achieve these goals? Find out how lean and 5S strategies can lead to a safer and more productive workplace.
What Is Lean Safety?
Lean safety is a strategy for ensuring a safe and efficient workspace. The “lean” concept focuses on reducing waste, such as unnecessary items or steps in a process.
Modern lean methodology sprang from the minds at Toyota in the mid-20th century. By the 1980s, other businesses began realizing the value of the model and started adopting it. Though lean principles originated in manufacturing, they complement and enhance safety in any organization.
Some fear that the lean approach is incompatible with safety protocols. These detractors assume that the focus of lean is to strip away as many tools and processes as possible. However, lean only intends to eliminate the nonessential. When you execute it correctly throughout your organization, it naturally leads to safer workplaces.
How Does 5S Work Within Lean Safety?
5S is a specific method for implementing lean safety. The system includes five core steps:
- Sort: Separate and eliminate anything unnecessary to your processes and keep only essential parts, tools, and instructions.
- Straighten (or “set in order”): Organize those essential parts, tools, and instructions to create an orderly workspace.
- Shine: Thoroughly clean and sanitize the workplace, getting rid of all dirt and clutter.
- Standardize: Document and schedule your procedures and rules for regularly sorting, straightening, and shining the work environment.
- Sustain: Ensure you preserve the 5S process with periodic audits, training, and improvements whenever possible.
The 5S methodology creates a continuously improving cycle of lean safety in any work setting, including manufacturing plants, construction sites, and transportation hubs.
What Is 6S?
Some people add a sixth S for “Safety” and call the process “6S” instead. This is usually only necessary in lean production processes to ensure safety is addressed.
In reality, safety is always a byproduct of a properly executed lean strategy, so the sixth S is more of a reminder and not really a separate step. With a lean safety strategy, all elements are working specifically toward a more secure work environment.
What Are the Benefits of Using Lean and 5S for Safety?
Lean and 5S help you achieve an all-around safer and more efficient work environment.
Fewer Accidents and Illnesses
Sorting and straightening each area regularly eliminates trip-and-fall hazards and other sources of accidents. Shining the area goes beyond a surface-level cleaning and prevents workers from encountering excess dirt and debris or interacting with hazardous chemicals or equipment.
You also lower the risk of on-the-job illnesses. The removal of nonessential items boosts ergonomics and reduces the risk of sprains and strains. Clean and clear spaces are not as overwhelming and contribute to better mental health and happier workers.
Granted, accidents may still happen. However, 5S lean safety means accidents are usually less severe and impactful.
A More Engaged Workforce
A well-crafted system for safety also improves employee participation. A set process gets better employee buy-in than generic orders to be clean and safe. Bringing employees into the Sustain part of the process gives them agency and a sense of ownership regarding your team’s safety.
Higher Productivity and Cost Savings
All of these benefits enhance your productivity because nothing is getting in the way and slowing down the work. Furthermore, you’ll lose less time and money on reporting and resolving accidents. As you fine-tune all of your processes, you should see cost savings throughout your company.
What Challenges Can Arise When Implementing 5S and Lean Safety?
Many work methodologies are effective in theory but fail in practice, usually due to low commitment or poor communication.
Breakdowns in Communication
Poor communication between employees and management causes lean safety programs to fail quickly. The company cannot efficiently identify and address safety issues. Failing to outline the importance and practical benefits of these programs also leads to low worker buy-in.
A Lack of Team Engagement
Safety professionals, in particular, may resist changing long-standing procedures that meet minimum requirements. They may fear that lean philosophies mean cutting essential safety techniques and that they will face consequences if problems arise.
After a strong start, a lean safety program can begin to slow down if your team doesn’t believe the system is delivering results. Complacency can set in after using the same protocols for a long time. Team members may feel the methodology is repetitive or overly time-consuming, which contradicts the objectives of lean safety.
What Solutions Are There to Common Lean Safety Challenges?
Ensure your lean safety program starts and stays strong with these tips.
Communicate Clearly
Lean is all about eliminating excess, so communication needs to be concise and easy to understand. Good signs and safety materials can effectively ensure employees have necessary reminders when they need them. Color-coded visual standards are an excellent way to communicate and reinforce lean safety and 5S principles.
Use Data and Technology To Engage and Incentivize Employees
Empower your employees by ensuring they have a convenient system for reporting areas of concern. If possible, give them a role in auditing. They should also be involved in implementing changes. You may need to invest in software that simplifies these interactions.
Software should also help you devise a system for measuring key performance indicators. This way, you can demonstrate the impact of your lean safety improvements and incentivize top performers.
Make Adjustments Gradually
Test new initiatives incrementally instead of making drastic overhauls. Too many changes too quickly can lead to hesitancy from your safety team. Testing and measuring new strategies can provide the data you need to get full buy-in from the crew.
Implement Lean Safety for a Healthier and More Productive Workspace
Lean safety is an effective way to improve your organization. An essential component of that strategy is good signage and materials. For products that perfectly suit lean safety and 5S strategies, check out our selection at ComplianceSigns.com for everything you need.