Case Study Novaris - Lean 5S

Situation / Driver:

  • Budget driven planning process was ineffective, inefficient and stifled creativity and visionary thinking
  • Failure to meet agreed timeframes within the planning and budget process
  • Inefficiency in development of the Annual Report


  • Trained Production staff in the Lean 5S methodology
  • Developed an overarching Implementation Plan to implement Lean 5S steps
  • Each Production team developed their own implementation plan around what they would do to follow the 5S methodology; the steps and actions, timeframes, responsibilities and roles etc
  • Implementation closely monitored
  • Teams visited each others’ area to see how they were progressing and learn from each other
  • Inspection process and visual standards are now being established to sustain the gains
  • Celebration event held where each team presented their “before and after”, shared progress and next steps and learnings
  • Presentation to the Board to communicate the approach, implementation and benefits achieved
  • Engineering are now implementing 5S within their areas of work
  • Workflow analysis is now being undertaken for the Production process using Lean waste tools

Benefits Achieved:

  • Increased focus on WHS practices
  • Increased employee engagement
  • Improved staff satisfaction and morale
  • Reduction in waste and increased productivity – approximately $23, 400 per year)
  • More professional company image

Lessons Learnt:

  • Plan to implement the approach
  • Communicate!  Enforce!  Reinforce!  Celebrate!
  • Get some quick wins happening