What Are the 5S Principles in Lean Manufacturing?
- The 5S method consists of five simple guidelines designed to create order and cleanliness in every workspace, whether in production areas or office environments
Raul Castro
Responsable de Producción y Mejora Continua
The 5S methodology is one of the most powerful tools within Lean Manufacturing, offering five simple yet transformative steps to improve organization and cleanliness in any workspace, whether in production areas or office environments. At COMSAN, these principles are a key part of our Comsan Business System (CBS) and play a fundamental role in the manufacturing of toilet seats.
The name “5S” comes from five Japanese terms that describe each phase of the process. Together, they help create safer, more efficient, and more stable workplaces. They also serve as the foundation for all continuous improvement initiatives.
The 5S in Lean Manufacturing: What Each Step Means
- Sort (Seiri) – Remove unnecessary items
The process begins by identifying which tools, materials, and objects are truly needed at each workstation. Anything that does not add value is removed, reducing clutter and freeing up valuable space. - Set in Order (Seiton) – Organize intelligentlyOnce the essentials have been selected, each item is given an optimal and accessible place. The goal is simple: “A place for everything, and everything in its place,” ensuring a smooth production flow—especially crucial in the manufacturing of toilet seats.
- Shine (Seiso) – Clean thoroughly
After organizing, the workspace is deeply cleaned. This step not only ensures hygiene but also helps detect equipment issues, leaks, or wear that could affect performance and product quality.
- Standardize (Seiketsu) – Make standards visible
This phase ensures that the cleanliness and organization standards are clear to everyone. Visual cues—such as color codes, markings, or shadow boards—make the process easy to replicate and maintain.
- Sustain (Shitsuke) – Build discipline and consistency
The final step focuses on turning 5S into a daily habit. Regular audits, clear responsibilities, and straightforward procedures help preserve the improvements over time.
Using the 5S methodology helps us create safer and more efficient workstations
Benefits of Applying the 5S in a toilet seat Manufacturing Plant
Implementing the 5S method provides significant and measurable advantages in factories dedicated to the production of toilet seats:
- Cleaner, more organized workstations that improve operational efficiency
- Safer and easier-to-manage work environments
- Extra space for new processes, tools, or materials
- Reduced time spent searching for tools or components
- Elimination of unnecessary items, lowering costs and preventing mistakes
- Better maintenance of machinery thanks to quicker detection of issues
- A strong culture of order and discipline across the company
To achieve the best results, it’s essential to apply the 5S steps in sequence and complete each phase fully before moving forward.
What We’ve Learned at COMSAN While Implementing the 5S Method
After years of applying Lean Manufacturing and the 5S principles in our facilities, we have identified several key lessons:
- Teamwork drives success: The involvement of the people who use each workstation is critical. Continuous training ensures sustained results.
- High impact on continuous improvement: The 5S form the foundation of most CBS improvement projects.
- Simple but transformative: Sorting, organizing, cleaning, standardizing, and sustaining are straightforward steps that significantly reshape how we work.
- Consistency is everything: A true 5S culture is built day by day, not through a one-time clean-up effort.
The implementation of the 5S methodology goes far beyond maintaining visual order. It is a comprehensive way of working that boosts efficiency, safety, and continuous improvement in every process. As part of the Comsan Business System, the 5S help us create more reliable, productive, and future-ready operations—essential in a competitive sector such as toilet seats manufacturing.
Adopting the 5S is the first step toward transforming workstations and strengthening a culture where every improvement counts and every person contributes to operational excellence.
