I work for a courier company and have been implementing 5S for over a year. 5S standards have been established throughout the parcel sorting operation. However we are facing issues in sustaining the performance as shop floor personnel consider this as added work. They keep putting parcels and roller containers, trolleys etc. in each other's locations. Corporate Management is strongly committed to 5S but middle management tends to only pay lip service & just ignore non-standard conditions. Things fall into place after top management does their Gemba Walk & sends strong messages on the deviations found. Things begin to fall apart again in a matter of days and fresh effort is required to put things back in place. Company also has a monthly 5S rewards program where top few areas are recognized every month. All shop floor personnel and management are trained on 5S and have taken part in 5S events that set standards for their area. In spite of all this, it has been difficult to sustain performance. Has anyone faced a similar situation? Is there something which we may not be doing right? What more would we need to do to get shop floor management & personnel to buy into this program?
One major stumbling block has been getting the buy in of the Operations Manager. In public he mentions the need for good standards but in reality he hardly practices it & walks by when deviations from standards are seen. The Operations Director too is a great advocate of 5S and has personally led a 5S Kaizen event in his area to demonstrate leadership. I feel the Operations Manager on the other hand is setting a bad example an since he doesn't really care too much, the people below him also behave the same way. The key issue I believe is changing his mind-set & behaviour. Appreciate any ideas on how to get him around. I have tried speaking to him, have showed him the benefits etc.. To him though my standards are too high. Problem is his standards are too low & he is only doing things half heartedly because the Operations Director sees great value in the program.