MentoCore6S Lean Manufacturing: the complete guide
6S extends the classic 5S workplace organization method with a sixth pillar — Safety — so operational visibility and a safer floor improve together. This guide explains every pillar, how to roll 6S out without slowing production, and gives you a free digital 6S audit checklist to run today.
What is 6S?
6S is a workplace organization methodology rooted in the Toyota Production System. The first five S's — Sort, Set in order, Shine, Standardize and Sustain — make abnormal conditions visible at a glance. The sixth S, Safety, makes hazard reduction an explicit part of every pillar instead of an afterthought.
Done well, 6S reduces walk time, eliminates searching, surfaces equipment problems before they cause downtime, and cuts recordable incidents — all without buying new equipment.
The six pillars
Sort (Seiri)
Remove anything from the workspace that isn't required to do the current job. Red-tag and stage doubtful items off the floor.
Set in order (Seiton)
A place for everything and everything in its place. Shadow boards, labeled bins, floor marking and point-of-use storage.
Shine (Seiso)
Cleaning is inspection. Operators clean their own equipment daily to surface leaks, wear and abnormal conditions early.
Standardize (Seiketsu)
Lock the first three S's in with visual standards, one-point lessons and recurring audits so the gains don't decay.
Sustain (Shitsuke)
Make the standard a habit — leader standard work, gemba walks, and a transparent scorecard the whole shift can see.
Safety
Bake hazard identification into every pillar: PPE, machine guarding, ergonomics, lockout/tagout and near-miss reporting.
Why add the 6th S?
- A cleaner, more organized floor is already a safer floor — 6S formalizes the connection.
- OSHA recordables drop when housekeeping standards are audited weekly with hazard items embedded.
- Operators report near-misses earlier because the audit gives them a structured channel.
- Insurance carriers and customer auditors (SQF, BRCGS, ISO 45001) score sites visibly higher.
Free 6S audit checklist
Use this as your weekly 6S audit. Each pillar is a quick pass/fail with space for a photo and a corrective action.
- No unused tools, parts or paperwork on the bench
- Red-tag area is reviewed weekly
- WIP at each station is within posted min/max
- All tools have labeled, dedicated locations
- Floor markings for aisles, equipment and pallet zones are visible and intact
- Stock is stored at point-of-use within an arm's reach
- Operator daily cleaning log is signed for the shift
- No leaks, drips or accumulated dust on equipment
- Cleaning supplies are stocked and accessible
- One-point lesson posted at each station
- Visual standards (photos) match actual setup
- Color-coded labels follow the site standard
- Weekly 6S audit completed and scored
- Audit findings have owners and due dates
- Last month's audit trend is posted at the board
- PPE is worn and available at each station
- Machine guards and e-stops are in place and tested
- Lockout/tagout points are labeled; LOTO log is current
- Near-misses from the last 7 days have been reviewed
Rolling out 6S in 30 days
- Week 1 — Pilot one cell. Pick the messiest, highest-traffic station. Photograph the baseline.
- Week 2 — Sort & Set. Red-tag together, build shadow boards, mark the floor.
- Week 3 — Shine & Standardize. Publish a one-point lesson and the daily clean log. Add the Safety items.
- Week 4 — Sustain. Run your first scored 6S audit. Post the result. Schedule weekly going forward.
6S vs 5S: which should you use?
5S is the original Toyota method and is enough if safety is already governed by a separate, audited program. Pick 6S when you want hazard identification, PPE compliance and lockout/tagout to be inseparable from housekeeping — which is the right default for most US manufacturers, food processors, and warehouses operating under OSHA 29 CFR 1910.