What are the six S's?
| Step | What it means | Example |
|---|---|---|
| Sort | Remove everything not needed for the current work | Red-tag a spare pallet jack nobody uses |
| Set in order | A labelled place for every item, arranged for use | Shadow board for line tools |
| Shine | Clean the area and inspect while cleaning | Wipe down a press and spot a hydraulic leak |
| Standardise | Write down how the area should look and who does what | Photo of the standard condition at the cell |
| Sustain | Keep it going with routines and audits | Weekly leader audit, results on the board |
| Safety | Find and remove hazards in the area | Clear walkways, guards fitted, spill kit stocked |
How is 6S different from 5S?
6S makes safety an explicit, audited step instead of assuming it follows from the other five. It is also called 5S+1. Some practitioners argue safety belongs inside every step, so many sites also write safety checks into each step.
Why does 6S matter beyond a tidy workplace?
Success with 6S depends equally on two things. One is setting the workplace up to expose problems, whether they sit in equipment, materials, finished product, information or the building itself: a leak shows on a clean floor, a missing tool on a shadow board.
The other is morale. 6S is a form of respect: people deserve a workplace that is pleasant to be in, feels good to walk into and that they can be proud of. That feeling is impossible somewhere that looks unloved, unkept, unmaintained and uncared for, and the neglect bleeds into every work process. When the area is kept civilised, clean and safe, with problems made visible, the same thinking carries back into every other process too.
How do you run a 6S audit?
A 6S audit checks one area against its standard, scoring each S with two to four questions answered by observation, and a photo for anything that fails. The safety questions cover blocked exits and walkways, missing guards, damaged leads, unlabelled chemicals, PPE stations and whether last time's hazards were fixed.
Example: a 6S audit on a packing line
A team leader audits a packing cell every Monday. The first five S's score well, but the safety step finds a stretch-wrap roll on the floor beside the conveyor, a trip hazard. It becomes an action for the shift supervisor, due Wednesday, and the area standard gains a marked place for it.
Why 6S slips
Like 5S, 6S fails at sustain: audits stop, findings never become actions, standards drift. Safety findings need an owner and a due date the same day, and a review at the next tier meeting.