5 s audit

5S AUDIT

PO Box 10222, Westbury, NY 11590 T: 516.414.3741 F: 516.941.0747 www.summitbizpro.com

Summit Business Solutions, Inc.

Form LEVC102.2

Introduction The purpose of this form is to help you establish order and visual management on your manufacturing floor. To do this you will utilize the 5S system, namely

1. Sort 2. Set in order 3. Shine 4. Standardize 5. Sustain

While it is easy enough to apply Sort, Set in order and Shine the key to this process is Standardization and Sustaining improvements. 5S is a foundational element of process improvement. It is second nature to the way world class organizations operate. The basic premise of 5S is to keep things where they belong. This maximizes worker productivity because less time is wasted looking for things. The use of visual controls such as color coding, signage, audible signals, lines and pictures further enhance productivity by allowing the factory to “speak” to its workers, thus minimizing the amount of supervision or indirect labor required. All this said, the question then becomes how neat is neat? Orderliness is often very subjective topic. This can create much confusion when several people express their opinions of how neat an area is kept. To minimize this subjectivity and allow a way for you to measure and set goals for orderliness we have developed this easy to follow 5S audit sheet. Refer to the next page for details on how to use this form. Be aware this can not be done from behind a desk, you will have to take a blank copy and go a target area on your manufacturing floor, spend some time observing the operation and fill in the scores. Use the scores to motivate your workers, establish 5S contests or high score of the month awards. The bottom line is making it fun for the workers and you will see a tremendous payback in reduction of overhead and floor space. If you require further information about how to use this form or about the 5S process please feel free to contact us via email at [email protected] or telephone at 1.516.414.3741.

5S AUDIT



Form LEVC102.2

How to Use This Form 1) Go to the target area. 2) Starting with the first S – Sort, check each item according to the description and rate it

on a scale of 0 through 4, where 0 is the worst and 4 is the best. Place a check mark in the appropriate box.

Score 1S No Check item Description 0 1 2 3 4 1 Materials or

parts Does the inventory or in-process inventory include and unneeded materials or parts?

2 Machines or equipment

Are there any unused machines or other equipment around?

3 Jigs, tools, or dies

Are there any unused jigs, tools, dies or similar items around?

4 Visual control Is it obvious which items have been marked as unnecessary?

5 Written standards

Has establishing the 5S’s left behind any useless standard?

SOR

T

Sub Total 3) When you complete an S, add the number of times you checked each column by the

column score weight then add up all your subtotal numbers and write that number in the category subtotal box.

4) Continue this process throughout each S 5) Add up each category subtotal to obtain your final score. 6) Post the score in a visible location in the target area using the 5S Score Sheet.

Category Subtotal

Item to be examined within a target area

Description of what you should evaluate

Score weight based on the description Add all

numbers from each column

Add all numbers from for a subtotal score per S

5S AUDIT



Form LEVC102.2

0=Very Bad 1=Bad 2= Average 3=Good 4=Very Good

Score 1S No Check item Description 0 1 2 3 4

1 Materials or parts

Does the inventory or in-process inventory include and unneeded materials or parts?

2 Machines or equipment

Are there any unused machines or other equipment around?

3 Jigs, tools, or dies

Are there any unused jigs, tools, dies or similar items around?

4 Visual control Is it obvious which items have been marked as unnecessary?

5 Written standards

Has establishing the 5S’s left behind any useless standard?

SOR

T

Sub Total


6 Location Indicators

Are shelves and other storage areas marked with location indicators and addresses?

7 Item Indicators Do the shelves have signboards showing which items go where?

8 Quantity Indicators

Are the maximum and minimum allowable quantities indicated?

9 Demarcation of walkways and in-process inventory areas

Are white lines or other markers used to clearly indicate walkways and storage areas?

10 Jigs and tools Are jigs and tools arranged more rationally to facilitate picking them up and returning them?

SET

IN

OR

DE

R

Sub Total

Score 3S No Check item Description 0 1 2 3 4 11 Floors Are floors kept shiny clean and free of waste,

water and oil?

12 Machines Are the machine wiped clean often and kept free of shavings, chips and oil?

13 Cleaning and checking

Is equipment inspection combined with equipment maintenance?

14 Cleaning responsibilities

Is there a person responsible for overseeing cleaning operations?

15 Habitual cleanliness

Do operators habitually sweep floors, and wipe equipment without being told?

SHIN

E

Sub Total

Category Subtotal

Category Subtotal

Category Subtotal

5S AUDIT



Form LEVC102.2

0=Very Bad 1=Bad 2= Average 3=Good 4=Very Good


16 Improvement memos

Are improvement memos regularly being generated?

17 Improvement ideas

Are improvement ideas being acted on?

18 Key procedures Are standard procedures clear, documented and actively used?

19 Improvement plan Are the future standards being considered with a clear improvement plan for the area?

20 The first 3 Ss Are the first 3 Ss (sort, set locations and shine) being maintained?

STA

ND

AR

DIZ

E

Sub Total

Score 5S No Check item Description 0 1 2 3 4 21 Training Is everyone adequately trained in standard

procedure?

22 Tools and parts Are tools and parts being stored correctly? 23 Stock controls Are stock controls being adhered to? 24 Procedures Are procedures up-to-date and regularly

reviewed?

25 Activity boards Are activity boards up-to-date and regularly reviewed?

SUST

AIN

Sub Total

GRAND TOTAL SCORE

Category Subtotal

Category Subtotal

5S AUDIT



Form LEVC102.2

5S Score Department Name

Previous Score

% Change (+/-)

Audit Date: Auditor Notes

Documents

5 s audit