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5S AUDIT CHECK LIST

5S DESCRIPTION Inspection Criteria Rating Y N 1 2 3 4 5 Comments Premises/Housekeeping Condition of floor & walkways Cleanliness of working area Supply of waste disposal bins Congestion of gangways and work areas Line-markings, signs and notices Standard / condition of lighting Levels of temperature Ventilation/extraction Amenities/sanitation Pollution/emissions Hazardous Materials Storage & Containers in control Labeling & identification Use/control COSHH assessments and controls in place Local exhaust ventilation adequate and functional Users competent with materials Signs/notices/procedures posted Disposal & spillage provided for adequately Machinery/Equipment Fixed/interlocking guarding in place Adequate controls & guarding on equipment Safety signs in place and in good condition Procedures posted for safe entry Preventative maintenance in place Isolation/lock off used as required Handling & lifting Electrical panels locked & portable appliances tested Training/knowledge Fire Extinguishers & equipment in place Alarms not obstructed and signed Procedure for evacuation and muster posted & up to date Access/egress - Exits/gangways clear Emergency lighting in place Awareness of employees Ignition sources identified and controlled Emergency/knowledge/action for specific processes Approved signs in place General Ergonomics Manual Handling aids in use Hand Tools Personal Protective Equipment in use Lifting gear used as required Ladders/platforms correctly used / stored Storage/racking

Scale: 1 = Poor 2 = Fair 3 =Good 4 = Very Good 5 = Outstanding

Total Points Average Rating (43 Questions in this Checklist) A rating of 3 or below requires a comment and should be entered on Team concern and countermeasure board for resolution.

Audit should be carried out weekly by supervisor and / or group leader as required Copy ofRetention completed sheet should be sent to the Superintendent Schedule GIS1 = 25:03

5S EVALUATION CHECKLIST
CHECK ITEMS
1. SORT

1. All items in the work area necessary (area free from mess and unnecessary objects) 2. Production and non-production materials properly kept and located 3. Cabinets,drawers and other storages contain only necessary items and sorted according to use (no items are placed above overhead storage cabinets) 4. Trashes and wastes properly sorted and disposed of 5. Red Tagging of unnecessary items evident in the area 6. No personal belongings (cellphone, wallets, etc.) in the workstations
2. STABILIZE

1. Location for every item in the work area is defined and every item in its defined location 2. Scrap/rejected/defective parts are kept in a properly labeled area until they are disposed of 3. There are floor markings where necessary, labels to all equipments including lubrication points, pipes and other items need to be labeled 4. Finished units and work-in-process are kept in a properly labeled area 5. All line side parts are properly and firmly labeled 6. All Hazardous materials stored and labeled properly 7. Min/Max for parts and other materials (where applicable) identified and adhered to
3. SHINE

1. Area free from dirt, dust and cob webs, including meeting area

2. Aisles, walkways, fire fighting equipments, and emergency exits are clear of stock, vehicles, trash and other obstacles, floors are free of tripping hazards 3. Area free from leak and spillage (water, oil and other fluids) from equipment, floor and faucet 4. Electrical wires, outlets, switches, and fixtures in order 5. Lighting fixtures are clean, functional and sufficient 6. A cleaning schedule such as 5S checklists defining individual task and schedule has been established and posted with targets
4. STANDARDIZE

1. All visual displays and visual controls conform with the plant's Visual Factory standards 2. QPS-OIS and WES are kept and posted respectively according to the area's standard while Work Balance Board reflects current process information 3. 5S Recovery action plans are tracked and closed according to defined schedules 4. SMT Boards contents are reviewed and updated including TDM cards 5. Daily Equipment Checklists (DEC) are updated
5. SUSTAIN

1. Recovery action sheet (or equivalent) posted with responsible persons and target date 2. Observable behaviors of partners in the area show compliance with 5S principles
RATING SCALE:

5 4 3 2 1

Outstanding; highly meets standard (Check Item) Meets standard, need to sustain the housekeeping system Standard not consistently applied Standard partially met Standard not followed

% RATING:

85% and above - Excellent, a model for others to follow 80% - 84% - Meets standard, need to sustain and improve 79% and below - Badly needs improvement

UATION CHECKLIST
OBSERVATIONS
RATING

TOTAL SCORE NOTE: Put NA under Rating column for Check Items Not % Applicable RATING Any of the Check Items with a Rating of 3 and below needs improvement plan Department / Area / Section: Audited By: Audit Date:

H
Workgroup 5S Audit Sheet
Date of audit... Team.... Shift.. Auditor(s).... .
Rating Y E N S O 1

5S Checklist
Sort

Inspection Criteria A Red Tag activity was used to identify or remove all of the items that do not belong or are no longer used. All Red tagged items were removed according to the flow chart.

Red Tag Process Red Tag Process

Visual Factory All line-side parts are labelled All gauges, tools and tooling fixtures have ladled locations and are Visual Factory stored correctly Stabilization Visual Factory Stabilization Visual Factory Stabilization Visual Factory Stabilization Visual Factory
Stabilise & Standardise

The min/max levels for line-side inventory are labelled and maintained Non-production materials being kept in the area are identified Designated walk areas are kept free of stock, vehicles, or other obstacles All scrap, rejects, and any defective parts are being kept in a properly labelled area until they are disposed of All finished goods and any work in progress is kept in properly labelled areas

Visual Factory The divider lines on the floor are clear and identifiable The following items are clearly labelled per Visual Factory standards: Fire / safety / evacuation notices Work Stations/Work Areas Equipment and Machines All hazardous materials e.g. lubricants, solvents and paint containers stored properly Pipes are colour coded for fluid type and direction of flow at the shut Visual Factory off points indicated All lube points indicated Operating range of all gauges is indicated Continuous Improvement Rotation direction is on all motors and all relevant equipment New techniques to help improve stability have been implemented in the area

Housekeeping Cleaning targets are identified Housekeeping Cleaning assignments are identified and individually assigned
Shine

Housekeeping Cleaning methods and procedures are identified and documented Work groups have identified and documented the right tool for the right Housekeeping job Machines, jigs & fixtures clean and in good order and clear of loose Housekeeping stock

Housekeeping The area is swept, wiped down, and clean at all times
Sustaining

Lighting

The lights in the area are working properly The area FTPM system being operated effectively Quality procedures being correctly completed & stored with Out of Control (o.o.c) identified Team boards are to plant standard and up to date Concern and Countermeasure sheets clear of delinquent issues

Error Proofing Quick Change Over

Error Proofing devices are identified with placard and listed Quick Change Over devices are identified and listed on the area log Quick Change Over times are being logged New Quick Change Over opportunities have been identified

Continuous Improvement QPS Action

Has any improvement activity been performed since last audit Is the QPS audit being carried out & current

Scale: 1 = Poor 2 = Fair 3 =Good 4 = Very Good 5 = Outstanding

Total Points Average Rating (36 Questions in this Checklist) A rating of 3 or below requires a comment and should be entered on Team concern and countermeasure board for resolution.

Supervisor .........

Group Leader.

Audit should be carried out weekly by supervisor and / or group leader and result entered onto team board sheet nu Copy of completed sheet should be sent to the Superintendent

t Sheet
Rating

.... .

2 3 4 5

Comments

red on Team

to team board sheet number 17