The Science of 5S: Why Visual Standards Matter in 2025

The Science of 5S: What Research Says About Making Standards Visible (2024–2025)

Making Continuous Improvement Visual.

In 2025, 5S remains one of the most widely adopted Lean foundations across manufacturing, logistics, healthcare and service environments. But while many organisations implement 5S, far fewer truly understand the science behind it — specifically, why visibility matters, and how current research (2024–2025) reinforces the value of clear visual standards.

This article brings together the latest evidence and practical insights to help organisations design 5S systems that actually work — from tool organisation and point-of-use layouts to 5S boards and cleaning stations.

1. Why 5S Still Matters in 2025

Recent research continues to support the impact of 5S on:

• Faster tool and equipment retrieval

• Fewer safety incidents

• Improved quality (due to less variation in process setup)

• Higher first-time-right rates

• Greater ownership and accountability

A 2024 review in the manufacturing sector found that 5S delivers measurable improvements when accompanied by visible, standardised layouts — not just written procedures or occasional audits. Visibility is the engine of sustained compliance.

2. The Science Behind 5S: Cognitive Load & Visual Search

Why do visual standards work? Because they reduce mental load.

Across human-factors studies, three scientific principles consistently appear:

Visual search efficiency

Humans locate items far faster when visual cues such as colour, shape and spacing are used consistently. Shadow outlines, grouped tools and colour-coded holders significantly reduce search time.

Spatial memory

We remember locations better than words. When every tool has a fixed, clearly marked home, cognitive strain drops and behaviour becomes natural.

Choice simplification

Clear visual rules reduce ambiguity. When standards rely on symbols, layout and colour (rather than lengthy text), compliance increases dramatically.

In short: visual management is not decoration — it’s human-factors engineering.

3. What the Latest Research Shows (2024–2025)

Across various studies in 2024–2025, several themes emerge:

Point-of-use positioning increases compliance

Teams are significantly more likely to follow 5S principles when tools and cleaning equipment are located where the work happens.

Visual cues outperform written standards

Organisations relying heavily on text or checklists saw lower audit scores than those using graphic cues: symbols, zones, coloured labels, and structured 5S boards.

5S adoption now spans non-manufacturing sectors

Healthcare, labs, hospitality and logistics are increasingly studied — with nearly identical outcomes: visibility drives reliability.

Sustained behaviour requires a visible feedback loop

The research emphasises that 5S works best when paired with visual audits, statuses and daily huddles — making performance visible.

4. Making Standards Visible: What Actually Works

Adoption improves dramatically when visuals are:

Clear

Bold headers, simple icons, and colour-coded zones reduce cognitive load.

Consistent

Research shows that maintaining a uniform visual “grammar” across boards, labels and layouts reduces confusion.

Accessible

5S boards should be located in natural pathways, not remote corners.

Active, not passive

A 5S board is not wallpaper. It should drive conversation, not just display information.

This is also where My Visual Management’s product set aligns strongly:

• 5S and 6S boards

• Cleaning stations

• 5S tag stations

• Audit boards

• Status indicators and magnetic visual controls

These tools embed standards visually into the environment, not just into documents.

5. Cleaning Stations: A Key Part of Modern 5S

While not the sole focus of 5S, cleaning stations appear repeatedly in recent research because they combine the principles of:

• Point-of-use

• Shadow placement

• Colour coding

• Standardised layout

• Visual checks

Studies show that when cleaning tools are stored visibly, in their correct place, the likelihood of completing daily checks increases significantly. The location, layout and colour of the station directly influence daily behaviour — far more than written instructions do.

6. Applying 5S Using Evidence-Based Design

Based on the latest insights, organisations can follow a simple, research-backed model:

1. Diagnose

Audit the current area. Identify search times, waste, clutter and unclear standards.

2. Design

Use clear visual rules:

• One colour = one category

• One shape = one tool

• One board = one purpose

• One location = one home

3. Display

Install visuals where the work happens: boards, holders, labels, zones, markers, status indicators.

4. Habit

Maintain standards with a visual audit board and short daily checks.

This approach makes the system self-reinforcing: the visuals themselves keep the environment in control.

Conclusion

The latest research is clear: 5S succeeds when the standards are truly visual.
When tools, layouts, cleaning equipment and processes are made visible, behaviour becomes more consistent — and continuous improvement becomes easier to sustain.

At My Visual Management, this principle guides everything we design:
Making Continuous Improvement Visual.