A simple way to train and implement 6S in a warehouse. We start by building shared language, then practice one S per week — with Safety last — and keep it alive with tiny daily habits.
6S is our simple way to make work easy, fast, and repeatable on the floor. We keep the language short and practical, so anyone can use it in a minute. We include Safety as a core S and train it last in the cadence so habits form first, then safety locks them in everywhere.
Sort
Keep what you need.
Remove what you don’t.
Set a red‑tag zone and criteria.
Decide: keep / move / repair / dispose.
Set in Order
A home for everything.
Place by frequency and flow.
Shadow boards, labels, lanes.
Photo the “good state”.
Shine
Clean to inspect.
See leaks, wear, damage early.
Log & fix root causes.
Post simple cleaning checks.
Standardize
Make the right way easy.
1‑page SOPs at point of use.
Visual cues and checklists.
Simple audits built‑in.
Sustain
Make it a habit.
Daily micro‑habits.
Weekly walk and reset.
Recognize and refresh.
Safety
Always first in action.
Trained last in cadence.
PPE, clear routes, LOTO.
Fix hazards fast.
Why it matters
When the floor is clear and tools are easy to find, people move safely and fast. Errors drop, flow improves, and teams feel in control. That is how we hit the plan and finish the day with energy.
Fewer incidents and near‑misses → more safe days.
Faster finding, picking, packing → less delay and stress.
Standard places and labels → fewer mistakes, quicker training.
Light audits → little checks, every day, by the team.
How we implement it — our rollout
We didn’t reinvent the wheel. 6S — The Path to Success™ is a simple, step‑by‑step way to train and implement 6S in a warehouse. First we build the culture with shared words. Then we practice one S at a time until it sticks. From Week 8 onward, we run tiny daily habits to keep gains alive.
Weeks 1–2 · Read & explain
Daily 2–3 minutes in the huddle: read a page from the booklet, explain, and collect one idea. Goal: common language and interest.
Weeks 3–8 · One S per week
Cadence: Sort → Set in Order → Shine → Standardize → Sustain → Safety. Each week we focus on one S.
From week 8 · Daily micro‑habits
After the six weeks of practice, we start the daily rhythms (60–120 seconds) to sustain results without heavy audits.
After week 8 · Keep it alive
Light audits by operators, weekly walk, near‑miss fixes, rotate focus S each week. Small improvements, often.
Complete 6S Implementation Plan
This is the full floor-first program adapted from your React plan. It keeps our cadence (Weeks 1–2 explain → Weeks 3–8 one S per week (Safety last) → Week 9+ sustain & expand) and adds day-by-day tasks, deliverables, and ongoing systems.
Phase 1: Culture Building · Weeks 1–2
Week 1: Introduction & Daily S Discussions
Daily 3–5 minutes
Introduce 6S (Sort, Set in Order, Shine, Standardize, Sustain, Safety) and why: efficiency, safety, pride.
Share success stories; set expectation: 2 weeks learning, then 6 weeks implementing. Emphasize: this is our project.
Daily focus prompts
Day 1 — Launch: purpose, benefits; agreements for respectful change.
Day 2 — Sort: what hasn’t been used in 6+ months?
Day 3 — Set in Order: what do you constantly search for?
Day 4 — Shine: what problems might cleaning reveal?
Day 5 — Standardize: how do we avoid sliding back?
Week 2: Deep Dive & Engagement
Day 6 — Sustain: habits, audits, visuals, recognition.
Day 7 — Safety: near‑miss review; how 6S prevents incidents.
Day 8 — Benefits: team pain points 6S can solve.
Day 9 — Pilot area: choose the first area; pick champions.
Day 10 — Ready to begin: recap and set Week 3 expectations.
Phase 2: Implementation · Weeks 3–8 (one S per week, Safety last)
Leadership: internal facilitators; supervisor 6S coaching; management training on strategy & resourcing.
Problem‑Solving & Continuous Improvement
If scores drop: same‑day root cause & fixes; extra Gemba; simplify standards; reinforce recognition.
CI process: idea board with weekly review; quick wins in days; monthly Kaizen; pilot, measure, standardize.
Common challenges: time pressure, ownership, confusing standards, visible leadership, sustaining past attempts — address openly.
Key Success Factors
Critical elements
Visible leadership commitment and participation.
Employee ownership through involvement.
Consistent daily/weekly audits without exception.
Immediate recognition and celebration of wins.
Expected benefits
15–30% improvement in space utilization.
10–20% increase in productivity.
50%+ reduction in search time.
Material reduction in incidents & near‑misses.
Remember
6S is not a project with an end date — it’s a continuous journey toward operational excellence. The culture you build in Weeks 1–2 and sustain through daily discipline determines long‑term success. Stay consistent, celebrate progress, and never stop improving.
Daily micro‑habits (60–120 seconds)
Sort
Pick one shelf: remove one unneeded item.
Move a seldom‑used tool to the red‑tag area.
Set in Order
Return two things to their “home”.
Label one bin or lane that’s missing a label.
Shine
Wipe a station and check for leaks/wear.
Log one issue you see while cleaning.
Standardize
Read one 1‑page SOP where you work.
Suggest one tweak to make the step clearer.
Sustain
Do the 5‑item self‑check before break.
Reset your area to “good photo” before handover.
Safety
Check PPE is on and intact.
Walk the nearest exit route; remove one blocker.
Supervisor Quick Start (pin or print)
Run a 2‑minute huddle with today’s S focus.
Observe the daily micro‑habit once per shift; remove blockers.
Fix <10‑minute issues on the spot; ticket the rest with owner & ETA.
Post one before/after photo per week on the visual board.
Recognize visible 6S behavior every shift.
KPIs & targets
Keep metrics few and visible. Mix behavior (leading) and outcomes (results).
Metric
Type
Target
How we collect it
Daily micro‑habit completion
Leading
≥ 90%
Tally on board
Time to find tool/part
Leading
≤ 30 s
Spot checks
Tickets closed within 48 h
Leading
≥ 95%
Ticket log
PPE compliance
Leading
≥ 98%
Gate + random checks
Near‑misses reported & fixed
Leading → Results
Reports up → incidents down
Near‑miss board
Pick/search time
Results
−50% search time
Time a typical pick
Area audit score
Results
≥ 90% sustained
Weekly 6S walk
Recordable incident rate
Results
Downward trend
H&S report
6S in a modern warehouse — our approach
6S brings order, speed, and safety to daily operations by combining five classic pillars of workplace organization with an explicit focus on Safety. In our rollout we start with language and stories to align the team, then we implement one pillar per week directly on the shop floor. Sort removes clutter that slows people down. Set in Order gives every tool and part a clear home so anyone can find and return it in seconds. Shine is not just cleaning; it is a short inspection that surfaces leaks, wear, and sources of defects. Standardize takes the friction out of doing things the right way with simple, visual standards at the point of use. Sustain keeps the gains alive through tiny daily habits and a weekly walk rather than heavy audits. Safety sits across all of this: routes are clear, PPE is available and used, and hazards are fixed fast. The result is a calmer workflow, shorter search time, fewer errors, and better training for new starters. This page includes a free A5 booklet and a set of A4 posters you can print and use in huddles. The complete plan lays out exactly what to do each week, what to deliver, and how to measure progress with a small set of KPIs. It is designed for operators first and supported by supervisors and managers who remove blockers, ticket issues, and recognize positive behavior. If you are starting from scratch, pick one pilot area, build momentum with visible before/after photos, and expand once the routine feels natural. With clear words and consistent micro‑habits, 6S becomes the way we work every day.
FAQ
Is this for operators or managers?
For operators first. Managers support by removing blockers, coaching, and making sure materials and tools are available. The words are simple on purpose.
How much time does 6S take daily?
Under 5 minutes to start, about 2 minutes to close the shift. The point is small, steady wins embedded in the work.
Do we need audits?
Yes, but keep them light. A short daily self‑check and a weekly walk are enough to keep 6S alive.
Why is Safety trained last?
Sort/Set/Shine/Standardize/Sustain create tidy, organized spaces that make safety easier to see and do. We comply from Day 0; we train Safety last to lock the habits across the site.