Table of Contents
5S System Guide
Everything you need to design, deploy, and manage a digital 5S program for your plant. From system setup to operator checklists to management dashboards -- this guide covers every feature.
Start Your 5S SystemWhat Is the 5S System?
The 5S methodology (Sort, Set in Order, Shine, Standardize, Sustain) is a proven workplace organization system that reduces waste, improves safety, and boosts productivity. Our 5S System tool digitizes this methodology for manufacturing plants, replacing paper checklists with a mobile-first platform that operators access via QR codes.
Key features include: a guided setup wizard with industry-specific templates, customizable checklists with 5 response types, QR code distribution for frictionless operator access, a supervisor review pipeline with corrective actions, SPC analytics (Pareto, p-chart, XmR), AI-powered weekly audit reports, and monthly management dashboards with executive summaries.
Who Is It For?
| Role | What They Do | How They Access |
|---|---|---|
| Quality Manager | Designs the 5S system, defines plant areas and checklists, runs weekly audits, reviews AI reports | Authenticated web app |
| Supervisor | Reviews daily operator submissions, approves or rejects checks, creates corrective actions, signs off shifts | Authenticated web app |
| Operator | Fills daily 5S checklists per area, captures photos, tracks personal streaks | QR code or shared link (no account needed) |
| Plant Manager | Views monthly management dashboard, area rankings, shift comparisons, and AI executive summaries | Authenticated web app |
Feature Guides
System Setup & Onboarding
Create your 5S system in minutes with our guided wizard. Choose your industry, define plant areas, and get pre-built checklists tailored to your work.
Checklist Editing & Customization
Customize checklists per area with 5 response types, photo requirements, critical item flags, and AI-powered suggestions.
Operator Daily Check
How operators fill daily 5S checklists via QR code or shared link. Covers identity, shift selection, pillar-by-pillar entry, and score confirmation.
Supervisor Review & Actions
Review operator submissions, approve or reject with reasons, create corrective actions, and sign off shifts.
SPC Analytics
Pareto charts, compliance trend p-charts, XmR control charts, and numeric item deep dives -- all powered by your daily check data.
Weekly Audit & Reports
Run weekly QM audits, generate AI-powered audit reports, and build evidence packages for ISO/IATF compliance.
Management Dashboard
Monthly trend analysis for plant managers: score rankings, shift comparison, action closure rates, and AI executive summaries.
Cost of Quality
Track scrap, rework, and downtime costs alongside 5S scores. See financial ROI with tiered cost tracking, currency support, and AI cost intelligence.
QR Codes & Distribution
Print QR codes, share WhatsApp links, and manage access tokens for your plant areas.
Typical Workflow
- Quality Manager creates the 5S system with the onboarding wizard
- Quality Manager customizes checklists per area
- Quality Manager prints QR codes and distributes them to the plant floor
- Operators scan QR codes and fill daily checklists
- Supervisors review submissions and create corrective actions
- Quality Manager runs weekly audits and generates AI reports
- Plant Manager reviews monthly dashboard and executive summaries
- Quality Manager enables Cost of Quality tracking to link 5S improvements to financial savings
How Scoring Works
The 5S System supports three scoring modes and five response types. Understanding how scores are calculated helps you design effective checklists.
Scoring Modes
- YesNo -- Simplest mode. Each item is Yes (pass) or No (fail).
- ThreePoint -- Three-level scale: 1 (Bad), 2 (OK), 3 (Good). Scores of 2 and 3 count as passing.
- FivePoint -- Five-level scale: 1-5. Most granular. Scores of 3, 4, and 5 count as passing.
Response Types
- Compliance -- Uses the system's scoring mode. The most common type for standard 5S items.
- Numeric -- Operator enters a decimal number (temperature, pressure, etc.). Passes if within configured min/max limits.
- Condition -- Operator picks from 2-5 predefined options (e.g., Good / Fair / Poor). First option is compliant.
- PhotoOnly -- Operator takes a photo. Documentation only, not scored.
- TextNote -- Operator enters free text. Documentation only, not scored.
Score Calculation
Per-pillar score = (passing items / total scorable items) x 100. Only Compliance, Numeric, and Condition items count toward the score.
Overall score = average of the 5 pillar scores (Sort, Set in Order, Shine, Standardize, Sustain).
Supported Industries
Each industry comes with pre-curated checklist templates and area archetypes specific to your type of work. Choose the closest match during setup; you can always customize afterward.