Purpose This case example illustrates how 5S (sort, set in order, shine, standardize and sustain) was implemented to reorganize a warehouse when business needs dictated that daily operations could not be shut down, even temporarily. Design/methodology/approach This case utilized an action research approach in which a researcher worked side-by-side with employees in the warehouse studied through daily/weekly site visits over nine months. This provided many opportunities for first-hand observation regarding the activities and progress of the warehouse’s 5S initiative. Findings This discussion highlights the lessons from this case that practitioners undertaking 5S initiatives should consider, including the risk of implementing 3S instead of 5S, the critical nature of the 5S team’s composition, the importance of planning for 5S activities, causes and impacts of delays (e.g., challenge of differentiating needed from unneeded items, losing momentum for the initiative), and the consequences of upper management’s statements and actions being misaligned. Practical implications Consideration of the challenges faced and critical success factors identified in this case example will help practitioners implement 5S more successfully in the future. Originality/value There are few, if any, discussions in the literature about the practical challenges associated with implementing 5S, such as how to reorganize a workplace when operations cannot be suspended.

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Lean,5S,Warehouse operations,Critical success factors

• Economics and Business - Social Sciences