6S Improvements

6S is a LEAN methodology that Fusion uses for developing and sustaining a productive work environment. This methodology is particularly helpful in increasing efficiency in factories as it increases organization, minimizes waste, and enables more accurate procurement processes.  The system is based on six alliterative concepts: Sorting, Straightening, Scrubbing, Standardization, Safety, and Sustainability.

While it may seem that factories should embrace these concepts as general best practices, most still overlook them due to poor management, lack of education, or even mere laziness.

In one factory, their initial state of cleanliness and organization was so dire that there was severe production inefficiency and waste.  In less than five weeks, Fusion’s consultants made dramatic changes to the operations and appearance of the factory.

The first three photos below show the unkempt, wildly disorganized conditions of the factory on Fusion’s first visit. The first photo shows a very disorderly warehouse.  The second photo shows a shelving unit with similar disarray: jugs of water for consumption are thrown next to an employee’s old shoes, beneath raw materials for use in production.  There was no organization at all, and no one accepted responsibility for it.  

Lastly, the third photo exhibits another common practice in this factory: putting all tools and materials on the floor where they would often get stained, broken, or damaged. The workers simply had no other way to deal with their production line items because there was no effective storage system in place.

Fusion’s first step towards improving the factory’s operations with the 6S system was to build accountability in the factory internally.  We created the 6S Team and built pride into its members by displaying their pictures on the wall.  

We then taught the committee members how to identify various issues and to work together to make positive changes in the factory.  

You can clearly see the improvements in the last three photographs on this page. Factory management has also recognized that there have been significant productivity gains solely due to better organization.