Using a 6S Lean Tool for a Safer, More Effective Workplace

In this solo episode of the Everyday Business Problems podcast, Dave Crysler breaks down one of the most popular lean tools in operations, 5S. Dave walks through the 3S, 5S, and 6S versions of this system, explaining what each step means and how to actually make it stick. Through personal stories, client examples, and a trip to Toyota's factory, Dave explores the difference between implementing a tool and embedding it into your culture. If you've ever struggled to sustain workplace organization efforts, this episode will help you rethink your approach and start with the right why.

What You'll Discover:

• The difference between 3S, 5S, and 6S, and why “sustain” and “safety” matter most.

• Why workplace organization fails without a clear why, what, and how.

• How tools like 5S support efficiency, quality, and safety when used intentionally.

• A behind-the-scenes story from Dave’s tour of Toyota’s Kentucky plant.

• How to avoid the common trap of short-term cleanup efforts that backslide over time.

• Practical tips to involve your team, build buy-in, and roll out 5S one step at a time.

• A free 5S audit template to help you get started or sustain your progress.

6S Audit Tool