Flat Surface Syndrome

There are a set of ailments that afflict many people when attempting to implement Lean.

One such ailment is the aversion to seeing a flat surface unencumbered by clutter, known as FSS or Flat Surface Syndrome. Some people have a tendency to see an open surface as an invitation to put something on it.

In non-work areas, this leads to clutter, and an inevitable collection of dust and debris accumulating around the items. It also presents a poor image of the company, which can be damaging when customers or investors are walking through.

In work areas, it leads to frustration as the space available to actually produce items slowly diminishes.

Reducing Flat Surface Syndrome

There are several steps you can take to reduce the impact of FSS.

Eliminate Flat Surfaces

Obviously, if you remove the flat surfaces, you remove the ability to put things there.

Label Work Areas Clearly

Create a specific color code or pattern for areas that are intended to be left clear. This is not a cure for FSS, as the unmarked area can still collect clutter, and people can easily violate the labels.

Tent Off Flat Surfaces

Some flat surfaces are hard to eliminate. The tops of cabinets, for example, are hard to get rid of. For those surfaces that are intended to be left unused, put a tent made out of cardboard on top of it. It will keep items from being placed there.

Do 5S Audits

Walking around and removing clutter is a last resort. It doesn’t prevent the problem, but it helps keep it in check. And the act of focusing on it can be helpful in changing behaviors. Just keep in mind that when the audits end, FSS will return.

The Origin of Flat Surface Syndrome

I’ve been using this term for years. I have a vague recall of coming up with the term during a training session I was presenting. Sometimes, though, memory fails, so I tried to look for the earliest reference I could find of it online. Turns out in the cursory search, my March 2009 article about FSS was the earliest reference I could find, but there are a whole lot of later references. If anyone finds an earlier reference, please let me know in the comments section.