5S in the Food Industry

Color-coded tools promote 5S programs

Sort, straighten, shine, standardize, and sustain. These five principles comprise the 5S lean manufacturing method that originated in Japan. While 5S can help any organization, the principles contained in the alliterative method should especially appeal to those in food processing for its ability to promote food safety through a clean, safe, and organized workplace.

5S principles are based on the idea that a well organized and clean workplace increases employee satisfaction, promotes worker safety, and decreases product waste. 5S relies on everything having its own place that’s easily identifiable. Like color-coding, 5S uses the idea of a “visual factory” that lets workers know at a glance where tools are and where they should be put back after they’re cleaning.

Sort

For the sort step, work areas should be cleared of things that aren’t needed daily. Discard junk that’s broken or simply not needed, along with broken tools. Items that are needed, but only on an infrequent basis, should be moved to storage. If an item is misplaced or stored illogically, it should be moved to a more convenient location.

Sorting can help minimize chances of cross-contamination and cross-contact by sorting food-contact and non-food-contact items apart from each other.
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Using Color-Coding for Food Safety and Organization

Lately, I’ve been doing a lot of consulting with food processors to build and improve color-coding systems in their facilities. Color-coding can be approached in a variety of ways and works well with a number of related programs. One such program is a lean manufacturing practice called 5S, which I encountered often in a previous position working in the steel industry.

I’m starting to see 5S used more often in food processing. Although I am not an expert in this system developed by the Japanese, I do know that the 5 S’s are Sort, Set in Order, Shine, Standardize, and Sustain. The aim is to eliminate waste, keep workspaces organized, and develop procedures that are consistently easy to follow. I can see why this set of guidelines is appealing to food processors. An organized processing facility is agreeable with inspection authorities, because it demonstrates that a food safety procedure is defined and in practice.

Color-coding for food safety

Color-coding is also commonly applied in conjunction with written food safety plans and HACCP programs to further enhance food safety. The purpose of HACCP and the CGMP regulations laid out in 21 CFR 110 is to identify and control hazards that could potentially impact the safety of food. Cleaning and food contact tools can potentially transfer hazards like pathogens and allergens throughout the facility, so it may be important to keep certain tools in designated areas. Color-coding supports this objective by clearly identifying where tools belong or what task they are designated to perform.
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