5S Diagnostic Checklist

5S AUDIT CHECKLIST AREA: workshop Last Audit Sco NA

Total Score # of Questions Average Score

Audit # Audit by:

SORT SET IN ORDER 18 20.5 6 5 3.0 4.1

SHINE 22.5 5 4.5

DATE: Next Audi STANDARDIZE SUSTAIN 26.5 14.5 7 5 2.9 3.8

TOTAL 102 28 3.7

SCORING GUIDELINES 0

1

2

3

ZERO EFFORT

SLIGHT EFFORT

MODERATE EFFORT

MINIMUM ACCEPTABLE LEVEL

3.5 (4)

4.5 (5)

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

SORT ACTIVITY DESCRIPTIONS 1)

2) 3)

4)

5)

6)

SCORE

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.

2 2

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

3

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.

3.5

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.

3.5

Tripping dangers such as electrical cables, etc. are removed from standing/walking areas. SET IN ORDER ACTIVITY DESCRIPTIONS

4 SCORE

7)

Locations for containers, boxes, bins, WIP, materials, etc. is clearly defined by painted lines and properly labeled (part number, quantity, etc.). 8) 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. 9) Paperwork is properly labeled and has a clearly defined and labeled location that is visible to the operators and away from work surfaces. 10) Equipment is clearly identified (numbered, named, color coded, etc.) and placed in a properly identified location. Critical maintenance points are clearly 11) marked. Furniture is clearly identified (numbered, named, color coded, etc.) and placed in a properly identified location. 12) Work areas requiring personal protective equipment are clearly labeled. 13) Stop switches and breakers are highly visible and located for easy access in case of emergency. 14) Fire hoses, fire extinguishers and other emergency equipment are prominently displayed and are unobstructed. 15) Working conditions are ergonomically friendly. Tools are stored at appropriate heights, lift assist devices are provided where necessary, etc. 16) The workplace layout accomodates easy exit in case of emergency. 17) Walkways and vehicle paths are clearly identified and unobstructed. Exits are clearly labeled and unobstructed.

3.5 NA 4 NA 4 NA NA NA 4 5 NA

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5S AUDIT CHECKLIST SCORING GUIDELINES 0

1

2

3

ZERO EFFORT

SLIGHT EFFORT

MODERATE EFFORT

MINIMUM ACCEPTABLE LEVEL

3.5 (4)

4.5 (5)

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

SHINE ACTIVITY DESCRIPTIONS

SCORE

18) Containers, boxes, bins, etc. are clean and not cracked, torn, or otherwise damaged. They are neatly stacked.

3.5

19) 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.

NA

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

4.5

21) Work surfaces (machines, workbenches, dies, and other equipment including electrical boxes) are clean and painted.

4.5

22) Floors are free from dirt, debris, oil, parts, hardware, empty boxes, packaging material, etc. Drains (if required) are properly located and unclogged.

5

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

5

24) 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. 25) All cleaning equipment is neatly stored and is readily available when needed. 26) 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. 27) Equipment safety concerns are clearly identified. Safety guards are painted, in good working condition and provide adequate protection. STANDARDIZE ACTIVITY DESCRIPTIONS

NA NA NA NA SCORE

28) Tools, equipment, paperwork, furniture, etc. are stored neatly in designated areas and are returned immediately after each use. 29) Documents are labeled clearly as to contents and responsibility for control and revision. The date and revision number are clearly visible. 30) Equipment maintenance records are visible and clearly state when maintenance last occurred and when next maintenance is scheduled. 31) Product waste (e.g. shavings, containers, liquids, wrappers, etc.) is consistently and often cleaned up and removed from the workplace. 32) 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). 33) The results of the previous audit are posted and clearly visible to the entire team. 34) Areas for improvement identified during the previous audit have been completed. 35) The work environment satisfies the requirements of the work being performed. Lighting (brightness and color), air quality, temperature, etc. SUSTAIN ACTIVITY DESCRIPTIONS 36) A member of Management has participated in a 5S activity such as an audit or other activity within the past 3 audit periods. 37) Recognition is given to teams who get involved in 5S activities. 38) Time and resources are allocated to 5S activities (e.g. designated daily/weekly clean-up time, 5S team leader, etc.) 39) All operators, team leaders, supervisors, etc. are assigned 5S activities to be completed at least once/week.

4.5 4.5 4.5 4 3 1 NA 5 SCORE 4.5 1 3 3

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40) The team took the initiative to make improvements to the workplace that were not identified during the last 5S audit.

3

AREAS FOR IMPROVEMENT

DATE

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

6-Feb-09

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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workshop 5S Result - Location: Score

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

3 SORT

3.5 4 4.5

5 SUSTAIN

SET IN ORDER

NA

STANDARDIZE

SHINE

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

5S Scoring Guidelines

SCORE 0 1 2 3

3.5 4 4.5 5

CATEGORY

DESCRIPTION There has been no 5S activity in this work area Zero Effort related to this criteria. Any 5S effort is probably the work of 1-2 people. There is no organized effort and plenty of Slight Effort opportunity for improvement. Some attempts have been made to implement 5S, Moderate Effort but efforts are temporary and/or superficial. The entire team is working on improving their 5S Minimum Acceptable implementation. Previous improvements are Level The level of 5S in thebecoming work areastandardized. is excellent. Above Average Results Although there is still room for improvement, the workplace is becoming world-class. Sustained Above After 3 consecutive scores of 3.5, a score of 4 may Average Results (3 be awarded. audits) The level of 5S in the work area is world-class, a Outstanding Results showcase for the industry. 5S is fully institutionalized in the workplace. Sustained Outstanding After 6 consecutive scores of 4.5, a score of 5 may Results (6 audits) be awarded.

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