Discover how 5S Principle Training transforms Malaysian workplaces. Learn step-by-step implementation and how to claim HRDC funding for your training. Free checklist included!
Introduction
In Malaysia’s competitive manufacturing and service sectors, disorganization costs companies up to 30% in lost productivity (MITI, 2023). The 5S Principle—a Japanese lean management method—solves this while being 100% HRDC-claimable.
At TIB Consultancy, we’ve helped companies implement HRDC 5S Principle training. Here’s how you can too.
What is 5S Principle Training?
5S originated from Toyota’s Production System (Toyota Global). It’s a systematic approach to workplace organization:
| S | Term | Action | Example |
|---|---|---|---|
| 1 | Sort | Remove unnecessary items | Factory: Clear obsolete machinery from production floor |
| 2 | Set | Organize essentials logically | Office: Color-coded filing system for HR documents |
| 3 | Shine | Clean and inspect daily | Hospital: Disinfection checklists for equipment |
| 4 | Standardize | Create uniform processes | F&B: Photo standards for kitchen tool placement |
| 5 | Sustain | Maintain through discipline | Plant: Weekly 5S audits with digital checklists |
Why 5S? The Shocking Cost of Disorganization
Malaysian manufacturers lose RM28,000 annually per employee due to:
- 22 minutes/day wasted searching for tools (MITI Study, 2023)
- 17% higher defect rates in cluttered environments
- 35% longer equipment changeover times
Industry-Specific 5S Blueprints
Manufacturing
- Tool Shadow Boards with QR inventory tracking
- Color-Coded Floor Markings (ANSI Z535 standards)
Healthcare
- Medication 5S:
- Red labels for expired drugs
- Nurse station “5-minute reset” drills
Office Environments
- Digital 5S:
- Email folder taxonomy
- Cloud storage cleanup protocols
HRDC Bonus: Industry-specific training qualifies for additional levy categories
5S Deep Dive: Beyond Basic Cleaning
Sort (Seiri) – HRDC Audit-Ready Approach
- Red Tag System:markdownCopyDownload1. Tag unused items with date (per [DOSH standards](https://www.dosh.gov.my)) 2. 30-day “quarantine zone” before disposal 3. Document process for HRDC claims
- Case Study: Johor PCB factory reclaimed 1,200 sq ft of space
Shine (Seiso) – OSHA-Compliant Methods
- 3-Tier Cleaning:LevelTaskFrequency1Basic wipe-downDaily2Equipment deep cleanWeekly3Facility-wide auditMonthly
HRDC Hack: Include cleaning time in training hours for levy claims
The 5S Principle is a Japanese methodology for workplace organization and efficiency, originally developed for Toyota’s production system. It focuses on eliminating waste, improving safety, and boosting productivity through five steps:
| S | Japanese Term | English | Key Action | Example |
|---|---|---|---|---|
| 1 | Seiri | Sort | Remove unnecessary items | Red-tagging unused tools |
| 2 | Seiton | Set in Order | Organize essentials logically | Shadow boards for tools |
| 3 | Seiso | Shine | Clean and inspect regularly | Daily equipment wipe-downs |
| 4 | Seiketsu | Standardize | Create consistent processes | Color-coded storage labels |
| 5 | Shitsuke | Sustain | Maintain discipline | Monthly 5S audits |
Why 5S Matters in Malaysian Workplaces
- Productivity Boost
- Reduces time wasted searching for tools/materials (up to 40% faster workflows).
- Cost Savings
- Cuts unnecessary inventory and storage costs.
- Safety Compliance
- Meets DOSH and NIOSH Malaysia standards for hazard-free workplaces.
- HRDC Funding
- Approved under HRDF levy claims
HRDC 5S Principle Training Success Story
| Metric | Before 5S | After 5S |
|---|---|---|
| Productivity | 72 units/hr | 101 units/hr |
| Safety Incidents | 14/month | 3/month |
| HRDC Claim | RM0 | RM12,450 |
“TIB’s training paid for itself through HRDC – we’re now expanding to all 3 plants.”
Step-by-Step 5S Implementation
- Check Eligibility:
- Companies with 10+ local employees in manufacturing/services
- Minimum RM3,000 HRDC levy paid
- Documentation:
- TIB provides HRDC-approved syllabus and trainer credentials
- Claim Submission:
- We guide you through the HRDC portal process
90-Day Sustainability Plan
- Weekly:
- 15-min team huddles
- Spot audits with digital checklists
- Monthly:
- KPI dashboard reviews
- “Best 5S Corner” competitions
HRDC Support: Refresher courses claimable every 6 months
Common 5S Mistakes in Malaysia
❌ “Sustain fails”: 68% of companies revert within 3 months
✅ Our Solution: Post-training 6-month support via:
- Digital audit tools
- Refresher courses (also HRDC-claimable)
Conclusion
5S Principle training isn’t just cleaning—it’s a strategic advantage with HRDC funding. Next steps:
- DM ‘5S’ for a free HRDC eligibility check
- Book a site assessment with our certified trainers
Learn More TIB Consultancy HRDC Claimable Programs : TIB Consultancy HRDC Programs
