The implementation of 5S is generally seen as confined to a classroom like training session with its use limited to just a one-time practice. This concept needs to be practiced as a daily activity and requires concentration, dedication and devotion for achieving the desired goals in the sense of the better performance and sustainability of a facility or a system. This should get embodied in the company’s culture itself with an aim of continuous improvement in its working environment and conditions. The observations made while working for over 16 years in real life situations involving a corporate office of a pharmaceutical industry and the production facilities of two distilleries indicate that an effective use of the 5S system requires a lot more on the job attention on the Segregation, Setting in order, Systematic Cleaning, Standardizing and Sustaining. The uniformity among the materials, methods, machines and manpower (4Ms) involved in the production of FMCG has direct bearing on product quality needs of the consumers. An effective Implementation of 5S therefore ensures proper harmony among the 4Ms which in-turn results in improved productivity and reduction in the consumption of resources and generation of wastes.

1. Improving Sustainability in FMCG through Effective
Implementation of 5S
by
Ajay Mahawar
HR/IR Consultant (Freelance) &
Former HR Manager (Asst.), United Spirits Ltd.
(Delhi – August 3, 2018)

2. What is 5S ?
 5S
 Sorting
 Straightening or setting in order
 Systematic cleaning
 Standardizing
 Sustaining
 Tool For
 Better performance and productivity
 Reduced resource consumption and waste generation
 Better conscientiousness among the employees/workers
 Better environment, health and safety
 Better sustainability

3. 5S: Current and Expected General Scenario
 Current Scenario
 Limited to classroom sessions
 Mostly one time practice
 More of preaching than practicing
 Expected Scenario
 To be practiced on daily/routine basis
 To be embodied in the company’s culture
 To be reviewed on regular basis
 To be modified/improved based on the reviews

4. Key Elements Concerning 5S in FMCG
 Risk of Contamination
 Raw materials
 Process chemicals
 Products
 Potential Contamination Sources
 Poor health and hygiene (human/system)
 Adverse weather conditions
 Materials scattering and cross contamination
 Poor house keeping

5. Key Elements Concerning 5S in FMCG (Contd.)
 Product Quality
 Ready availability of standards
 Timely training
 Awareness on quality assurance (criteria, assessment and Control)
 Sustainability
 Conscientiousness
 Keenness for knowledge on 5S
 Keenness for implementation of 5S
 Keenness for conceiving 5S as work culture

6. Sorting
 Sorting criteria and its awareness
 Criteria
 Output quality standard
 Output quality assessment
 Output quality control
 Awareness
 Health and hygiene measures
 Procedures
 Products
 Materials

7. Sorting (Contd.)
 Sorting Methodology
 Ensuring health and hygiene requirements
 Ensuring absence of any infectious or contagious disease among workers
 Work completion as fast as possible within the thresholds 5S
 Segregation, proper storage and use of materials in process where
possible
 Separate storage for materials to be sold
 Separate storage for materials to be disposed as wastes
 Sorting and storage of disposable wastes as per the permitted regulatory
options

8. Straightening or Setting in Order
 Quality standard documents
 Quality assessment methods/equipment/instruments
 Quality control methods/equipment/instruments
 Materials , products , wastes
 Health and hygiene control methods/equipments/instruments
 Accidents and fire fighting equipments. Procedures, alert systems etc
 On site medical facility, first aid etc
 Medical history records of workers
 Medical check up schedule
 Off site medical arrangements such as ambulance, nearest hospital alert
system
 Compliance requirements check lists, guidelines etc

9. Shining or Systematic Cleaning
 Material, Methods, Machines
 Sorting area
 Storage and use area
 Approach to the material sorting, use and waste storage areas
 Tools/equipments/instruments
 In-house medical facility
 Records/files/documents/work place
 Process zones and associated office space , fittings and fixtures
 Workers and working environment
 Change Rooms and Canteen facility
 Medical facility (on-site as well as off-site)
 Medical records

10. Standardizing
 Uniformity in 4Ms (Materials, Methods, Machines and Manpower)
 Preparation, Documentation and Ready Availability of Standards
 Materials, Methods, Machines
 Sorting
 Straightening
 Shining or Cleaning (including the system Hygiene)
 Man Power Knowledge
 Skills
 Attitudes
 Health

11. Sustaining
 Implementation of 4S
 Regular Reviews and Revisions of 4S
 Process changes
 Product changes
 Market demand changes
 Manpower Changes
 Resource consumption and waste generation
 Accidents including fires and material spills
 Performance to price ratios
 Trainings and refresher courses on 5S for all workers/employees
 General awareness of the environment, economic and social aspects of
sustainability of the overall system

12. Concluding Remarks
The uniformity among the materials, methods, machines and manpower
(4Ms) involved in the production of FMCG has direct bearing on product
quality needs of the consumers. An effective Implementation of 5S
therefore ensures an effective harmony among the 4Ms which in-turn
results in improved productivity and reduction in the consumption of
resources and generation of wastes.