5S Diagnostic Checklist

5S AUDIT CHECKLIST

AREA: workshop Audit # DATE:

Last Audit Sco NA Audit by: Next Audi

SORT SET IN ORDER SHINE STANDARDIZE SUSTAIN TOTAL

Total Score 18 20.5 22.5 26.5 14.5 102

# of Questions 6 5 5 7 5 28

Average Score 3.0 4.1 4.5 3.8 2.9 3.7

SCORING GUIDELINES

0 1 2 3 3.5 (4) 4.5 (5)

ZERO EFFORT SLIGHT EFFORT MODERATE EFFORT

SORT ACTIVITY DESCRIPTIONS SCORE

1) 2 2) 2 3) 3 4) 3.5 5) 3.5 6) ₄

SET IN ORDER ACTIVITY DESCRIPTIONS SCORE

7) _3.5 8) _NA 9) ₄ 10) _NA 11) ₄ 12) _NA 13) _NA 14) _NA 15) ₄ 16) ₅ 17) _NA MINIMUM

ACCEPTABLE LEVEL RESULTS (3 AUDITS)ABOVE AVERAGE RESULTS (6 AUDITS)OUTSTANDING

Only the required spare parts, materials, WIP, etc. are present at the workstation. Items not required to make the current product are removed from the workplace.

Only the required tools are present at the workstation. Items not required to make the current product are removed from the workplace.

Only the required paperwork is present at the workstation. Out-dated or otherwise unnecessary posters, memos, announcements, reports, etc. are removed from the workplace.

Only the required equipment is present at the workstation. All obsolete, broken or unnecessary equipment, shelves, lockers, workbenches, etc. not required to make the current product is removed from the workplace.

Only the required furniture is present at the workstation. All broken or

unnecessary chairs, shelves, lockers, workbenches, etc. not required to make the current product is removed from the workplace.

Tripping dangers such as electrical cables, etc. are removed from

standing/walking areas.

Locations for containers, boxes, bins, WIP, materials, etc. is clearly defined by painted lines and properly labeled (part number, quantity, etc.).

Tools have a designated storage location that is within reach of the operator.

The location is properly labeled and tools can easily be identified if absent.

Paperwork is properly labeled and has a clearly defined and labeled location

that is visible to the operators and away from work surfaces.

Equipment is clearly identified (numbered, named, color coded, etc.) and

placed in a properly identified location. Critical maintenance points are clearly marked.

Furniture is clearly identified (numbered, named, color coded, etc.) and placed

in a properly identified location.

Work areas requiring personal protective equipment are clearly labeled.

Stop switches and breakers are highly visible and located for easy access in

case of emergency.

Fire hoses, fire extinguishers and other emergency equipment are

prominently displayed and are unobstructed.

Working conditions are ergonomically friendly. Tools are stored at appropriate heights, lift assist devices are provided where necessary, etc.

The workplace layout accomodates easy exit in case of emergency.

Walkways and vehicle paths are clearly identified and unobstructed. Exits are

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5S AUDIT CHECKLIST

ZERO EFFORT SLIGHT EFFORT MODERATE EFFORT

SHINE ACTIVITY DESCRIPTIONS SCORE

18) 3.5 19) NA 20) _4.5 21) 4.5 22) 5 23) ₅ 24) _NA 25) _NA 26) NA 27) NA

STANDARDIZE ACTIVITY DESCRIPTIONS SCORE

28) _4.5 29) _4.5 30) _4.5 31) ₄ 32) 3 33) ₁ 34) _NA 35) ₅

SUSTAIN ACTIVITY DESCRIPTIONS SCORE

36) _4.5

37) 1

38) ₃

39) ₃

MINIMUM

ACCEPTABLE LEVEL RESULTS (3 AUDITS)ABOVE AVERAGE RESULTS (6 AUDITS)OUTSTANDING

Containers, boxes, bins, etc. are clean and not cracked, torn, or otherwise

damaged. They are neatly stacked.

Tools are kept clean and in good working order. Where possible, tools are stored

in a manner to keep them clean and free from risk of damage.

Paperwork is not torn, kept clean and protected from dirt.

Work surfaces (machines, workbenches, dies, and other equipment including

electrical boxes) are clean and painted.

Floors are free from dirt, debris, oil, parts, hardware, empty boxes, packaging

material, etc. Drains (if required) are properly located and unclogged.

Walls, partitions, railings, etc. are painted and kept clean.

There is a schedule showing times, frequency and responsibilities to clean areas of the workplace such as windows, corners, walls, doors, top of cabinets, etc. All cleaning equipment is neatly stored and is readily available when needed. All personal protective equipment is maintained in sanitary and reliable condition and is properly stored in a easily accessible and labeled location when not in use.

Equipment safety concerns are clearly identified. Safety guards are painted, in

good working condition and provide adequate protection.

Tools, equipment, paperwork, furniture, etc. are stored neatly in

designated areas and are returned immediately after each use.

Documents are labeled clearly as to contents and responsibility for control and

revision. The date and revision number are clearly visible.

Equipment maintenance records are visible and clearly state when maintenance last occurred and when next maintenance is scheduled.

Product waste (e.g. shavings, containers, liquids, wrappers, etc.) is consistently

and often cleaned up and removed from the workplace.

Preventive measures have been implemented to ensure the workplace meets

5S guidelines (e.g. systems that do not allow waste to accumulate such as containers to collect product debris from machines).

The results of the previous audit are posted and clearly visible to the entire team.

Areas for improvement identified during the previous audit have been

completed.

The work environment satisfies the requirements of the work being performed. Lighting (brightness and color), air quality, temperature, etc.

A member of Management has participated in a 5S activity such as an audit or other activity within the past 3 audit periods.

Recognition is given to teams who get involved in 5S activities.

Time and resources are allocated to 5S activities (e.g. designated daily/weekly

clean-up time, 5S team leader, etc.)

All operators, team leaders, supervisors, etc. are assigned 5S activities to be completed at least once/week.

40) ₃

AREAS FOR IMPROVEMENT

DATE

Continue effort on sorting out the unneccessary items in the office and under and on t

6-Feb-09

The team took the initiative to make improvements to the workplace that were

not identified during the last 5S audit.

Recognition system should be develop to suppor the implemenation of 5S in order to ensure the sustainable application of this program

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0 The level of 5S in the work area is excellent. The workplace is becoming world-class. 1 workshop 2

3

5

5S Scoring Guidelines

SCORE CATEGORY DESCRIPTION

0 Zero Effort

1 Slight Effort

2 Moderate Effort 3

3.5 Above Average Results

4

4.5 Outstanding Results

5

There has been no 5S activity in this work area related to this criteria. Any 5S effort is probably the work of 1-2 people.

There is no organized effort and plenty of opportunity for improvement. Some attempts have been made to implement 5S,

but efforts are temporary and/or superficial. Minimum Acceptable

Level

The entire team is working on improving their 5S implementation. Previous improvements are becoming standardized. The level of 5S in the work area is excellent. Although there is still room for improvement, the workplace is becoming world-class. Sustained Above

Average Results (3 audits)

After 3 consecutive scores of 3.5, a score of 4 may be awarded. The level of 5S in the work area is world-class, a showcase for the industry. 5S is fully institutionalized in the workplace. Sustained Outstanding

Results (6 audits) After 6 consecutive scores of 4.5, a score of 5 may be awarded.

SORT

SET IN ORDER

SHINE

STANDARDIZE

SUSTAIN

5S Result - Location:

workshop

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