 📖 Introduction
In the world of manufacturing and operations, 5S (Sort, Set in Order, Shine, Standardize, Sustain) is often seen as a simple housekeeping tool. But when applied properly, it becomes a powerful strategy that delivers measurable improvements in efficiency, safety, and profitability.
In this article, we’ll explore the benefits of 5S with benchmarks based on global standards — not guesswork.
📦 1. Space Utilization
Benchmark: 5–15% of floor space can be freed.
Benefit: Reduced need for expansion or rental space.
Example: Freeing 1,000 sq. ft. in a 10,000 sq. ft. plant.
đź•’ 2. Productivity & Time Savings
Benchmark: 25–55% reduction in wasted time.
Benefit: Higher throughput with the same workforce.
Example: Saving 10 minutes per operator per shift can equal an extra hour/day across 6 operators.
 
đź“Š 3. Inventory Reduction
Benchmark: 5–20% reduction in active stock.
Benefit: Lower carrying costs (20–30% annually) and less expired stock.
Example: A ₹1 crore inventory can save ₹5–20 lakhs/year.
âś… 4. Quality Improvements
Benchmark: 5–15% reduction in scrap/rework.
Benefit: Lower customer complaints and warranty costs.
Example: ₹30 lakh annual scrap reduced by ₹1.5–4.5 lakhs.
🦺 5. Safety
Benchmark: 10–40% reduction in incidents.
Benefit: Fewer injuries, lower compensation, improved morale.
Example: A workplace with 10 incidents annually could cut 1–4 incidents.
🔧 6. Maintenance & Equipment Life
Benchmark: 10–30% reduction in unplanned downtime.
Benefit: More uptime, longer machine life, fewer disruptions.
Example: Cutting downtime by 30 hours saves â‚ą4.5 lakhs/year at â‚ą15,000/hour.
🌍 Why These Ranges Are Reliable
These benchmarks are supported by:
JIPM TPM case studies (Japan)
Lean Enterprise Institute (USA)
OSHA safety benchmarks
APICS supply chain studies
This ensures the results are not theoretical but globally validated outcomes.
đź–© Interactive 5S Savings Calculator
To make these benefits tangible, we’ve developed a 5S Benefit Calculator.
👉 Employees enter their current state (floor space, inventory value, downtime, etc.).
👉 The calculator applies global 5S benchmarks to show tentative savings in money and time.
🎯 Final Takeaway
5S is not just “cleaning the workplace.” It’s a strategic improvement framework proven worldwide to deliver:
5–15% space savings
25–55% productivity gain
5–20% lower inventory cost
5–15% fewer defects
10–40% fewer accidents
10–30% less downtime
đź’ˇ These results translate into lakhs in annual savings and a safer, more motivated workforce.
So, the question is: How much are you leaving on the table by not implementing 5S?
Implement 5S, buy 5S items from www.breval.co.in.
Contact rds@breval.co.in, info@breval.co.in for 5S consulting, auditing, training & implementation.
Get 5S & Workplace management mobile application LeanKia (Download from playstore). Click Here
