SEIKETZU (STANDARDIZATION): CHARACTERISTICS AND EXAMPLES - JOB - 2025

The Seiketsu (standardization) is the fourth stage of the Japanese method 5S lean manufacturing. Its objective is to establish standards in the work methodologies related to the first three 5S stages (Seiri, Seiton and Seiso) and in operations in general.

In the methods, tools and processes that must be shared with other people, it is necessary to renounce personalistic tendencies. This responds to the need to act in favor of helping each other to understand things, thus sharing a common vision.

In this way, all employees will know how to organize and maintain their workplace in an efficient and safe way, with clear instructions and well understood by all.

Without standardized work, you will never be able to continually improve processes or find out where errors are occurring.

For everyone to understand a standardized system, staff must be trained and even subjected to periodic testing to ensure they understand it properly. The system design should facilitate their learning.

characteristics

Seiketsu does not refer to an activity, but to a state or condition. It consists of building a robust set of procedures to maintain the first 3S.

However, the true purpose of the Seiketsu is not only to standardize what has been done in the first three stages of 5S, but to achieve standardized work, ensuring that the most efficient ways of doing things are performed in a repeatable way, through instructions. documented work procedures (standard operating procedures).

Seiketsu is also about visual concept: everyone should be able to distinguish between normal and abnormal conditions at a glance.

Standardization

Standardization makes abnormalities and unusual situations stand out. If a group of cleaning machines are arranged neatly in a row, with a place for each, then it will be noticeable if one is missing.

Similarly, if all the parts inspected have a label affixed in a standard and visible place, it can be easily detected when any are missing to be examined. Colored labels also allow you to highlight items that have failed your inspection.

Labeling, color coding, and other visual tools, along with written procedures, are all part of the standardization process.

There are many possibilities for creativity in standardization: using positioning markers, transparent protective covers that give visibility, liquid crystals and other electronic codes that change according to changing conditions, arrows to show routes, etc.

Benefits

Reduce training time

Similar situations are documented similarly, basic tasks are performed in each workgroup, and experienced co-workers can explain things to newcomers.

Reduce or eliminate confusion

Each worker clearly knows their tasks and responsibilities

How to implement the Seiketsu?

- The roles and responsibilities of all staff must be documented and clear. Management must provide sufficient time for staff to develop and implement changes.

- Staff must be willing to accept changes and help implement them. For staff to adopt standard processes, all members of the company must be informed.

- The more group discussion meetings you have when you are implementing and documenting what the standard is or what the standard should be, the greater the possibility of successfully maintaining it.

- The previous three stages of 5S should be standardized, ensuring that cleaning becomes part of the routine process. For this, time, equipment and documented instructions must be provided to personnel.

- Color code the different areas, functions, etc., to make things as clear as possible, with common codes throughout the company.

- Ways must be found to extend the use of standard colors and images to convey important information quickly and consistently. The main benefit with this is increased safety in the workplace.

- Have standard ways of storing tools and equipment in their cells so that anyone in the company knows where to look for things. Have specific areas and color codes for documentation so that they are common to all areas.

- Have operators document the workflow. These documents will ensure consistency between work shifts and the different operators.

- By having the same operators define and write the instructions, you avoid any problems with them, either because they do not understand the work instructions or because they do not agree with the described methods. In addition, they are more motivated by having more control over their own working methods.

Examples

Use of standardized signs

All "Exit" signs look the same, but are different from "Entrance" signs or "Restrooms" signs, to make the message easy to understand quickly.

Some of this has been incorporated into society: a red circle with a diagonal stripe to indicate "don't come in here" or "don't do this," or labels with a skull and crossbones for poisons.

Cleaning the workplace

Each worker should have a set of daily cleaning tasks, such as:

- Clean the tools before storing them on their respective shelves.

- Sweep a designated area of ​​the floor.

- Clean and inspect the machinery used during that shift.

- Store the elements of the workplace properly: for example, by placing the lids on the containers.

- Turn off or unplug power tools, as needed.

- Clean dust from work surfaces.

- Visually check that everything is in place.

This set of actions should not add more than five minutes to each worker's set of daily routine tasks. The key is that this becomes routine.

For management to enforce standards, they must be documented. Photographs of the orderly workplace should suffice.

Use of colors

The use of colored adhesive labels can be set to be visibly affixed to products reviewed by quality insurers on a production line, to indicate their particular quality status. For example:

Red Label

The product does not meet the quality specifications. It must be discarded.

Yellow label

Product under observation. Requires additional testing or rework.

Green label

Quality approved product.

Ideally, make wearing these labels part of everyday life in all work areas.

Colors can also be used on people, with different colors on helmets, badges, shirts, etc., to indicate the function or hierarchical position of the worker.

This, for example, will make it easy to see where electricians are working. It also makes it clear when someone is doing a job for which they are not qualified.

References

1. Oskar Olofsson (2018). Seiketsu in Lean 5S. World Class Manufacturing. Taken from: world-class-manufacturing.com.
2. Changing Works (2018). The five Ss: Number 4: Seiketsu (standardization). Taken from: syque.com.
3. Lean Manufacturing Tools (2018). Read 5S Seiketsu. Taken from: leanmanufacturingtools.org.
4. Micazen Consulting & Technologies Inc. (2018). 5S - Standardize (Seiketsu). Taken from: micazen.com.
5. Juan Felipe Pons (2018). Keys and Tips to Implement the 5S Methodology. Read Construction Blog. Taken from: leanconstructionblog.com.