5S METHODOLOGY IN ACTION: BRINGING ORDER TO MY WORKSPACE – DIFFERENT WAY TO COMMUNICATE

Physical Vapor Deposition (PVD) systems require a dedicated mechanical room because many of their components—pumps, power supplies, chillers, and gas lines—are located at the backside. In addition, shelves are needed for spare parts, tools, and consumables. Without a structured system, these areas can quickly turn into cluttered and inefficient spaces.

When performing maintenance on PVD equipment, technicians often lose time searching for the right tool or part. This not only slows down operations but also increases the risk of errors or delays. To address this challenge, many manufacturing facilities apply the 5S methodology—a lean management technique designed to improve workplace organization, safety, and efficiency.

In this blog post, I’ll share how I’m applying 5S principles to my own production floor and mechanical room. But before diving into my journey, let’s break down what the five “S” steps mean and why they matter for sustainable workplace organization.

Understanding the 5S Methodology

The 5S methodology comes from lean manufacturing and is widely used in production environments to improve efficiency, safety, and organization. Each “S” represents a Japanese word that describes one step in the process. When applied together, they transform messy spaces into clear, structured, and easy-to-manage work areas.

Here’s how I understand and apply them in my own PVD production floor and mechanical room:

1. Sort (Seiri) – Remove the unnecessary

In a mechanical room, it’s easy to keep unused fittings, broken spare parts, and outdated tools “just in case.” In reality, these items only take up valuable space. With 5S, the first step is to separate what is essential from what is not.

On the production side, consumables such as crystals, used evaporator materials, and worn components also pile up quickly. These should be collected in proper disposal bins instead of left scattered around. Sorting is about making room for the things that truly matter.

2. Set in Order (Seiton) – A place for everything

Once only the necessary items remain, each tool and part must have a designated location. In PVD maintenance, speed is critical—you don’t want to waste time searching for a wrench or a spare vacuum seal.

In the production area, shelves for consumables, tools, screws, and materials are a must. When everything has its place, you don’t even need to think—you can find tools almost by muscle memory, like Yoda using the Force in Star Wars. That’s the power of a well-organized workspace.

3. Shine (Seiso) – Clean and inspect regularly

Dust, oil, and leftover parts can easily build up in a mechanical environment. Shine is not just about cleaning—it’s also about preventive maintenance.

Regular cleaning should include not only the front side of the PVD machine but also the backside, where many critical components sit. If resources allow, one team member can even be assigned to clean and check the backside regularly.

Inspection should follow a routine: every few hours, daily, or weekly depending on your setup. Key checkpoints include the chiller unit, high vacuum pumps, electrical cabinets, water lines, and pressures. Using a log sheet to track these values helps detect issues early. From my point of view, cleaning and inspection are the most critical parts of 5S.

4. Standardize (Seiketsu) – Create rules and consistency

Labels and shelves work best when they are applied consistently. Standardization means defining the rules: which color labels mean what, where documentation is stored, and how often cleaning is done.

Once you find the right routine, it almost feels like playing a game. Each day, you check off boxes on your list—like collecting coins in a video game. These small, repeated actions keep the system alive.

5. Sustain (Shitsuke) – Make it a habit

The hardest part of 5S is not starting—it’s keeping it alive. Without discipline, both the mechanical room and production area will slowly fall back into disorder.

To sustain 5S, you need to train your team and explain why it matters. When people understand that workplace organization directly affects quality, safety, and efficiency, they are more likely to follow through. 5S is not just a system—it’s a culture.

Why 5S Matters for PVD Systems

In environments with complex equipment like PVD systems, every minute counts. 5S reduces wasted time, minimizes mistakes, and improves workplace safety. Most importantly, it makes the workspace accessible to any team member, whether they are new or experienced.

Applying 5S methodology on the production floor and in the mechanical room has shown me that organization is not just about neatness—it is about building a system that saves time, reduces stress, and improves quality. In complex environments like PVD systems, where every tool and spare part matters, 5S creates clarity and consistency that everyone can rely on.

What I’ve learned is that 5S is more than a checklist—it’s a way of thinking and communicating. The system you build today can guide your colleagues tomorrow, and even speak for you when you’re not there. It’s a culture that connects people across roles, shifts, and even generations of supervisors.

For me, this is just the beginning of the journey. I’ll keep refining the system, adding structure, and learning how to sustain it better. If you’re also struggling with clutter, disorganization, or wasted time on your production floor, I encourage you to give 5S a try. You might be surprised by how much it changes—not only your workplace, but also the way your team communicates.