5S is more than a tidy workspace. For decades, it has been considered the essential starting point of any KAIZEN™ transformation. But is it still relevant today – and does it really deliver measurable results? A review of the most current 5S research helps answer that question with surprising clarity: From manufacturing to healthcare, and from small factories to digital workspaces, the data reveals that 5S not only works – it adapts, scales, and creates lasting value when done right.

In this article, we highlight 10 key insights from recent studies that every business leader should know before launching or refreshing a 5S initiative.

1. 5S Remains the Cornerstone of KAIZEN™ – Across Sectors

Although 70% of research still focuses on manufacturing, studies show that 5S has successfully migrated to other sectors like healthcare, government, and office environments. Its core principles – sort, straighten, scrub, standardize, sustain – translate well across settings, proving that visual order, efficiency, and discipline are universal performance drivers.

2. The Gains Are Real and Measurable

Quantitative results from the reviewed studies demonstrate strong performance improvements:

• 30% more storage space
• 10% reduction in unproductive time
• 12.91% space saving in ceramics storage
• Production system efficiency rising from 67% to 88.8%

In healthcare, while metrics tend to be more qualitative, results included higher patient satisfaction and improved workplace safety.

3. The Fifth S – Sustain – is the Most Difficult and Most Important

Nearly all studies flagged “Sustain” as the hardest step. While early phases (Sort, Straighten, Scrub) can yield fast wins, embedding 5S into culture takes 6–12 months and requires ongoing reinforcement. Without this final step, most improvements gradually fade.

4. Initial Results Can Be Achieved Quickly

Leaders can expect early improvements within 8–12 weeks. For example, a manufacturing firm improved storage by 30% in just 8 weeks. However, studies caution that without long-term planning, these results will plateau or reverse.

5. Healthcare and Services Succeed with Custom Adaptations

Adaptations are key when moving 5S outside of manufacturing:

• In clinical labs, visual management enhanced safety and cleanliness
• In offices, 5S was applied to digital file systems and workflows
• In customer-facing areas, visual appeal and flow took precedence

The principle? Keep the core of 5S, but adjust the practice to match the context.

6. Management Commitment Is a Must-Have

40% of the studies identified top management commitment as the most critical success factor. Visible leadership engagement – especially during “gemba walks” and audit follow-ups—reinforces that 5S is more than just housekeeping.

7. Engaged Employees Drive Lasting Results

In the most successful cases, employees were not just trained – they were co-creators of the process. Teams who helped define standards and participated in structured workshops showed the highest levels of motivation and ownership.

8. A Structured Rollout Works Best

Research confirms that a phased, structured approach beats ad-hoc implementation:

1. Start with a pilot area
2. Focus on the first three S’s – sort, straighten, scrub
3. Develop visual standards
4. Build auditing routines
5. Connect to broader KAIZEN™ activities

This model reduces confusion, clarifies ownership, and sustains improvements longer.

9. You Can – and Should – Apply 5S Digitally

Although less studied, digital 5S is gaining traction. One UK study reported a 15% reduction in time spent searching for digital information after applying 5S to IT systems. Think: file sorting, naming conventions, and shared folder structures.

If your business is hybrid or remote, digital 5S is no longer optional – it’s essential.

10. ROI Becomes Visible in 3–6 Months

Want to justify the time and budget? Use this framework to track impact:

• Direct gains: Space savings, faster search times, lower inventory
• Indirect gains: Fewer defects, better safety, improved morale
• Implementation costs: Training, supplies, audit time

The majority of case studies show that organizations recover their investment within a few months—and then continue compounding gains over time.

5 Most Common Mistakes in 5S Implementation

Despite its simplicity, 5S often fails due to predictable errors. The most frequent include:

1. Treating 5S as a one-off “clean-up day”
2. Weak leadership support after launch
3. Skipping the training—or training only on tools, not mindset
4. Using a copy-paste approach without sector adaptation
5. Over-documenting and under-empowering

Avoiding these pitfalls can significantly boost your 5S success rate.

Final Thought: 5S is Not Just a Tool. It’s a Mindset.

Masaaki Imai once said: “5S is both the first and last step in each KAIZEN™ journey.” The research supports this view. 5S is not just a method to start improvement – it becomes the foundation for everything that follows. When done with structure, commitment, and creativity, 5S unlocks measurable results in any sector – and makes excellence visible, one step at a time.

References

1. Jaca, C., Viles, E., Paipa-Galeano, L., Santos, J., & Mateo, R. (2014). Learning 5S Principles from Japanese Best Practitioners: Case Studies of Five Manufacturing Companies. DOI:10.1080/00207543.2013.878481
2. Kanamori, S., Sow, S., Castro, M., Matsuno, R., Tsuru, A., & Jimba, M. (2015). Implementation of 5S Management Method for Lean Healthcare at a Health Center in Senegal: A Qualitative Study of Staff Perception. Global Health Action. DOI:10.3402/gha.v8.27256
3. Singh, M. G., Padhy, M., Kumar, S., Solanki, H., & Gupta, R. (2022). Implementation of 5S Management Method for Lean Healthcare in Clinical Biochemistry Laboratory of a Government Hospital in India. International Journal of Health Sciences. https://doi.org/10.53730/ijhs.v6nS3.9489
4. Warwood, S., & Knowles, G. (2004). An Investigation into Japanese 5‐S Practice in UK Industry. https://doi-org.emedien.ub.uni-muenchen.de/10.1108/09544780410551287
5. “Implementation of 5S Methodology in the Small Scale Industry: A Case Study.” (2015). International Journal of Advance Research and Innovation. https://ijari.org/assets/papers/3/1/10.51976ijari.311543.pdf