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This paper explores the concept of workplace organisation and the role of safety. Specifically, the objectives of the study were to identify the role of safety within 5S and to test how the extension of the method (to 6S) can explicitly and effectively integrate safety with productivity and quality. An action research approach enabled the development, execution and data collection of a 6S method at a manufacturing company located within the UK. The 6S method was developed based on results from early experiments with 5S and a critical review of the literature. The research was conducted using a five-phase framework: 6S concept development; 6S process development; recording 6S quantitative data; 6S improvement activities and recognition; and 6S success measurement. The results of this study show a visible productive change in different work areas of the case organisation along with creating a safer work environment for both employees and visitors. The testing of the 6S method achieved tangible results in relation to productivity, efficiency and safety, which included: improved housekeeping; improved usage of floor space; good visual management and control; and a safer environment supported by a systematic approach.
