EPP Europe P2.2023

» PCB & ASSEMBLY
The 5S lean manufacturing methodology in PCB production
Improve benchtop cleaning,
reduce waste with 5S
Developed in Japan, 5S is a workplace organisation method used in physical
manufacturing to eliminate waste. Elizabeth Norwood, Senior Chemist at cleaning
solutions provider MicroCare, reveals how this lean, clean philosophy can be
usefully applied in benchtop cleaning practices.
extremely valuable process in PCB production, and
especially benchtop cleaning. Adopting the 5S lean
manufacturing method can help PCB manufacturers
achieve better cleaning results at the benchtop, and
thus increase efficiency and yield by reducing the
number of faulty components and boards that land
in the scrap pile.
Optimising cleaning
tools and workflow
will lead to increased
efficiency and reduced
waste
Although PCB shortages may be starting to stabilise,
but the electronics industry continues to
feel their impact. Exacerbating this issue for PCB
manufacturers is the fact that the electronic components
market continues to rapidly expand – with the
sector predicted to grow by USD 122.44 billion (EUR
116 billion) between 2022 and 2027, at a CAGR of
7.02%. To avoid delays, PCB fabricators must find
flexible and innovative strategies to ensure production
continues. Options may include modifying designs or
using alternative parts, but there is a more obvious
solution: increase efficiency by decreasing waste.
Electronics manufacturers must implement
methods to ensure every electronic component is optimally
utilised. An effective way to do this is to
adopt tried and tested lean manufacturing processes
such as the 5S methodology. This approach benefits
all kinds of production environments and can be an
Source: MicroCare
What is 5S?
The 5S philosophy can be summed up as: ‘a place
for everything and everything in its place’. The name
refers to five Japanese words beginning with ‘S’ that
represent a 5-step process to organize the working
environment. These terms can be translated into 5
comparable English words:
• Seiri/Sort: Separate tools/components that are
necessary from those that are not.
• Seiton/Set: Organise and categorise tools/components
for ease of access and ease of use.
• Seiso/Shine: Clean up the working environment.
• Seiketsu/Standardise: Create standards and guidelines
to uphold these practices.
• Shitsuke/Sustain: Follow the first four ‘S’s on a
long-term basis by always maintaining the correct
procedures.
Toyota first introduced something akin to the 5S
methodology into its production in the 1950s – hoping
to reduce manufacturing waste and inefficiency.
It was discovered that by applying what later became
known as the 5S concept, production ran more
effectively because the workplace was clean and
well-organised. This made it easier to see defects, all
of which ultimately reduced waste and improved
quality and output.
The 5S strategy offers a large number of benefits
to companies that adopt it. As well as reducing
waste and optimising productivity, it also helps to
enhance safety, improve quality and reduce costs. It
is estimated that efficiency gains of 10% to 30% can
be achieved using this method.
44 EPP Europe » 11 | 2023