5S Audit Checklist - Shopfloor

8/11/2019 5S Audit Checklist - Shopfloor

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IED-GE-OC-FO-102

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DEPT:______________________________________

AREA/SECTION:______________________________________ DATE:_________________________________

YES (/) NO (X)

PRODUCTION AREA - ENTRANCE (Note: Applicable for food facilities)

1 With hand washing area, properly equipped with soap and hand dryer.

2 With footbath sufficient with width, length and height to disinfect lower half of

boots.

3 Are free from insects and pests.

4 Area free from insects and pests.

5 With proper signages.

RACKS/ OPEN SHELVES

6 Are free from dust, stains, cobwebs, spillage, rust and are well-maintained.

7 Are labeled properly.

8 Items stored inside drawers are properly arranged.

9 Items stored match the identification of label.

10 No food and personal items stored.

CABINETS / TOOL BOX

11 Are free from dust, stains, cobwebs, spillage, rust and are well-maintained.12 Are labeled properly.

13 Items stored are properly arranged.

14 Items stored match the identification of label.

15 No food and personal items stored.

16 Closed at all times when not in use.

17 Tools and small instruments are cleaned and returned to designated storage after

use. No defective tools and small instruments.WORKING TABLES

18 Are free from cobwebs, rust and are well maintained.

19 Are free from dust, stains and spillage after any activity.

20 Items on top of tables are kept clean and properly arranged and stacked when

not in use.

CONTROL PANELS

21 Are free from dust, stains, cobwebs, drippings, rust and are well-maintained.

22 Are properly labeled.

CONTROL PANELS

23 No items stored inside except for control panel manuals.

24 Panel doors are closed at all times except during maintenance and inspection.

SEATING UNITS

25 Are kept clean and in good condition at all times.

26 Nothing is placed on top of chairs

PARTITIONS

27 Are free from rust, cobwebs and well-maintained.

28 Nothing hanged on it except signage.

WINDOWS / DOORS / GATES

29 Are free from dust, stains, cobwebs, rust and posted materials.

30 Are in good condition at all times (including venetian blinds and curtains).

31Doors and gates are free from obstructions.

32 Two-way doors are provided with directional signs.

33 Windows and doors provided with screen to prevent entry of flies and other

insects. (Note: For food facilities)

WINDOWS / DOORS / GATES

34 Doors are wide enough to ensure no contact between door jambs and means of

conveyance. (Note: For food facilities)

35 Doors are self-closing. (Note: For food facilities)

36 Doors are non-permeable. (Note: For food facilities)

37 Doors fit perfectly when closed. (Note: For food facilities)

FLOORS

38 Are free from litter, stains and drippings after any activity.

39 Are free from protrusions, nails, unsecured wires, cords and other obstructions.

40 Are free of slip, trip or fall hazards.

41 Safety markings are visible at all times.42 No missing or damaged tiles. No peeled off epoxy paint.

43 No missing canal covers/strainers.

44 No clogged drains and stagnant water.

45 Easy to clean. (Note: For food facilities)

FLOORS

46 Made up of non-slippery ceramic tiles, cement or synthetic materials. (Note: For

food facilities)

47 Free of cracks and indentation. (Note: For food facilities)

48 Junction with wall is rounded. (Note: For food facilities)

WALLS

49 Are free from stains and cobwebs.

WORKPLACE STANDARDSCONFORMS ?

REMARKS/STATUS

5S AUDIT CHECKLIST FOR SHOPFLOOR

STANDARDS


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YES (/) NO (X)WORKPLACE STANDARDS

CONFORMS ?REMARKS/STATUS


50 Are free from memos, notes and notices.

51 No big cracks or holes.

52 No graffiti.53 Only the following can be hanged/nailed on walls:

o work-related/decorative framed materials

o directional and instructional stickers/signs

o business and other permits

o religious items

54 Are non-permeable. (Note: For food facilities)

55 Are easy to clean. (Note: For food facilities)

WALLS

56 Are free of cracks and crevices. (Note: For food facilities)

57 With rounded corners. (Note: For food facilities)

CEILINGS

58 Ceilings, roof, insulation, light diffusers and air ducts are free from dirt, stains andcobwebs.

59 No roof leaks and flaking of paint.

60 No missing or peeled off boards. No damaged insulation.

61 No cracked or missing light diffusers.

62 No busted light bulb.

AISLEWAYS AND PASSAGEWAYS

63 Are clear and unobstructed.

64 At least 28 inches wide.

65 Permanent aisles and passageways clearly marked.

66 Covers and/or guardrails provided when aisled or passageways are near open

pits, tanks, vats, ditches or similar hazards.

PLATFORMS / SCAFFOLDING

67 Working platforms at least 24 inches wide.

68 '4-inch toeboard provided along all sides.69 Non-skid flooring provided.

70 Access gates self-closing and locking.

71 Equipped with standard guard rail if over 10 feet above floor.

72 Sound, rigid footing for scaffolds.

73 No accumulation of tools or materials.

74 No altering or moving of scaffolds in use.

STAIRWAYS


76 Steps uniform in height and tread depth.

77 Are free from litter, dust, stains, cobwebs, rust and spillage.

78 Are free from unsecured wires, cords, obstructions and tripping hazards.

STAIRWAYS

79 Stairs having 4 or more risers are provided with standard hand rails on open

sides.

80 Open risers if less than 9-inch tread depth.

81 No damaged stairway risers and handrails.

82 Surface slip resistant.

83 Long flights broken by platforms.

84 Outdoor stairs have grating type treads.

EXITS/EGRESS

85 Sufficient exits for prompt escape (at least 2 exits from one area).

86 Exit doors not locked.

87 Routes and exits clearly marked.

88 Exits adequately illuminated.

89 Approaches to exits ubobstructed.

90 Flammables kept out of exits.

EXITS/EGRESS


92 Open outward onto level floor.ROADWAYS

93 Surfaces in good condition.

94 Sufficient width and vertical clearance provided.

95 Standard signs and marks present.

96 Rail sidings in good condition.

VENTILATION

97 Adequate means provided.

98 Air inlets and openings arranged to minimize escape of contaminants.

99 Enclosures provide continuous inward air flow.

100 Separators provided if air is recirculated.

101 Hoods draw air away from people and connected to exhaust system.

102 Ductwork made of non-combustible material, sealed and adequately supported,

Note: Any new item that will be hanged/nailed on walls are to be referred first to Admin.

Services for approval.


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VENTILATION

103 Ventilation facilitates removal of objectionable odor, heat and moisture and entryof clean fresh air. (Note: For food facilities)

NOISE EXPOSURE

104 Protection provided when sound levels exceed standard.

LIGHTING

105 Walking and working areas adequately illuminated during periods of occupancy.

106 Lighting fixtures clean.

107 Illumination level sufficient for detail of work performed; no shadowing or glare.

108 Lighting properly covered with non-glass material. (Note: For food facilities)

109 Emergency lighting of all exit routes not naturally lighted.

STACKING AND STORAGE

110 Aisleways and access paths clear and unobstructed.

111 Small or irregular shaped items properly blocked, interlinked, with proper

limitations in heigt of storage.112 All stacks stable and secure against sliding/collapsing.

113 Proper drainage in storage area.

114 Storage area clean and cleared of foreign objects/materials.

STACKING AND STORAGE

115 Racks and platform load limits posted and observed.

116 With sufficient pallets, shelves and racks to hold usual inventory.

(Note: For food facilities)

117 Raw materials are stored according to prescribed storage condition.


118 Proper separation of food and non-food items. (Note: For food facilities)

119 Stored materials are properly tagged with identification, delivery and expiry date.

(Note: Applicable to food facilities)

120 Follows FIRST IN, FIRST OUT system in issuing raw materials and finished

goods. (Note: For food facilities)

121 Separate storage area for raw materials and finished goods.


122 Proper ventilation system. (Note: For food facilities)

123 Provision of pest and insect control. (Note: For food facilities)

124 Area facilitates smooth traffic for the reception and release of materials.


125 No condensation. (Note: For food facilities)

MATERIALS HANDLING

126 Containers in good condition.

127 Pallets and skids of correct type and in good condition.

MATERIALS HANDLING

128 Materials on pallets are properly piled.

129 Chains, slings and ropes adequate for loads and in good condition.

130 Lifting equipment properly stored.

CHEMICALS AND FUELS131 Tanks/drums made of s teel or appropriate material, adequately supported,

grounded and bonded.

132 Limited to 2,500 gallons if above ground.

133 Tanks adequately venred and provided with pressure relief valves.

134 Adequate spill containment.

135 Proper spill absorbent materials provided.

136 Container corrosion prevention provided.

137 Temperature controlled to prevent boiling.

138 Adequate storage cabinets provided; fire resistant and vented.

139 Storage heated by means not constituting a source of ignition.

COMPRESSED GASES

140 Stored upright and secured against falling over.

141 Segregated by contents and legibly marked.

142 Caps in place and hand tight.143 Protected against rust/corrosion.

144 Stored away from heat sources.

145 Stored away from stairs, elevators, and egress routes.


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HAND AND PORTABLE TOOLS

146 Tools, electrical cords and air hoses in proper general condition.

147 Stored properly when not in use.148 Guards and safety devices serviceable.

149 Electrical grounding or double insulation serviceable.

150 Power tools equipped with constant pressure switches.

151 Tool retainers installed on pneumatic tools.

152 Adjustment correct.

HAND AND PORTABLE TOOLS

153 Load rating sufficient for work performed.

MACHINE TOOLS AND GUARDING

154 Mechanical power transmission guarded.

155 Pinch points, in-running nip points, and points of operation guarded.

156 Fixed guards secured in position.

157 Interlock guards operative.

158 Automatic guards properly adjusted.

159 Operating controls guarded against inadvertent actuation, locked and keyremoved when not in use.

160 Emergency stop buttons operational, correctly positioned, labeled, and color

coded.

161 Isolation and lock-out provided for servicing.

162 Guards provided for rotating parts, chips or particles, sparks, kickbacks, etc.

163 Operator and service manuals available.

CONVEYORS

164 Gears, shafts, pulleys guarded on nip points.

CONVEYORS

165 Drop guards installed to catch falling material.

166 Emergency stop controls adequately located and operational.

PRESSURE VESSELS

167 Meters and controls located on operating floor.

168 Safety valves operational.

169 Drains clear and freeze protected.

170 Inspection certificate/label appropriate to type.

171 Pipes, connections, vessels free of dents, notches and severe scratches.

172 Shields, platforms and landings as appropriate.

VALVES AND MECHANICAL CONTROLS

173 Are color-coded and properly identified with water-proof labels.

174 Operational

175 Readily accessible.

PIPELINES

176 Are color-coded for identification of hot and cold water and steam.

177 Pipelines for hot water and steam are properly insulated.

178 Are properly marked and self-draining.

SIGNS AND TAGS

179 Hazard warning, directional and informational signs and tags used where thereare immediate dangers, potential hazards, or there is a need for general

instructions.

180 Signs and tags consistent in use throughout the facility.

181 Tags affixed to all defective equipment not secured against use.

COLOR CODING

182 Red color coding used to indicate immediate danger.

183 Yellow color coding used to indicate changing conditions.

184 Orange color coding used to indicate areas under modification, hazardous parts

when guards removed.

185 Green color coding used to indicate safety insructions and first aid equipment.

186 Blue color coding used for general information signs and tags.

187 Color coding systems used to indicate fluid and gas system contents.

MATERIALS LABELING188 Standard labels affixed to all containers of hazardous substances in storage and

use.

189 Standard labels affixed to vehicles transporting hazardous materials.

190 Labels legible and visible.

MULTI-PURPOSE TANKS

191 Are free from dust, stains, leaks, cobwebs, rust, unofficial stickers and well-

maintained.


193 No items placed on top and beneath.

194 Equipped with level controls to prevent overflow.

MACHINERY AND EQUIPMENT

195 Are free from dust, stains, leaks, cobwebs, rust, unofficial stickers, unnecessary

drippings of oil or grease and well-maintained.


197 No loose spare parts/tools/personal items lying on top, inside and beneath the

equipment.

198 Are in good operating condition.

MACHINERY AND EQUIPMENT

199 All moving parts are guarded.

200 Machine guards/doors are closed when machine is operating except during

trouble shooting.


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201 Are installed at a minimum of 12 inches (greater distance for large equipment)

from walls, support structure and other stationary structure. (Note: For food

facilities)202 Equipment and instrument location facilitate one-way process flow.


203 Equipment and instruments/accessories are made up of non-corrosive materials.

(Note: Applicable for food facilities)

204 Facilities and equipment do not transmit toxic substances, odor and taste to

products. (Note: For food facilities)

205 Under controlled temperature as required by controlling authority.

(Note: Applicable for food facilities)

206 No material made of wood and breakable glass. (Note: For food facilities)

APPLIANCES

207 Are free from dust, stains, unofficial stickers and well maintained.

ELECTRICAL

208 Switches and outlets are clean and operational.

209 No broken switches and outlets.210 No hanging connections, exposed or faulty wiring.

211 All equipment and appliances must be turned off and set aside after use.

212 Wiring of equipment and appliances are properly laid out. No octopus

connections.

ELECTRICAL POWER SYSTEMS

213 High voltage and control panels closed and secured.

214 Control panels identified and accessible.

215 Wiring, insulation and fixtuers in good condition.

216 Explosion-proof fixtures provided in dusty or flammable vapor areas.

217 Flexible cords free of splices.

WARNING SYSTEMS

218 Fire/Emergency alarm systems operational.

WARNING SYSTEMS

219 Hazard warning systems on appropriate vehicles and equipment.

220 Overpressure warning systems on pressure vessels.

221 Overtemperature warning systems on fired pressure vessels, hazardous material

storage, powered equipment.

222 Warning signs and devices for railway sidings available.

EMERGENCY INSTRUCTIONS

223 Operational placards/decals on emergency controls (on-off, open-close, etc.)

224 Emergency instructions at primary telephone in each work area.

225 Fire Hazard symbols on facilities containing hazardous substances.

FIRE PROTECTION

226 Potable extinguishers appropriate to type of materials readily available.

227 Extinguishers inspected monthly.

228 Fire hoses properly mounted and accessible.

FIRE PROTECTION

229 Fire equipment visibly marked.

230 Fire doors, lids and shutters in good condition with fusible links intact.231 Sprinkler heads have minimum clearance from materials and furnishings.

232 Sprinkler master control valves accessible and locked open.

233 Personal protective equipment for fire brigade members in good condition.

EYE BATHS AND SHOWERS

234 Readily available and accessible in areas where caustic/corrosive chemicals are used.

235 Water supply provides 15 minute flush at comfortable temperature.

236 Proper signs and instructions.

237 Flushed frequently to eliminate contaminants.

FIRST AID KITS / STATIONS / EQUIPMENT

238 Located as prescribed by legislation and organizational medical policy.

239 Adequate materials and equipment available and properly located.

240 Electrical safety items included in high voltage areas.

DRESSING ROOM, TOILET AND WASH ROOM

241 Toilet equipped with the following at all times:o toilet paper

o liquid soap in soap dispenser/container

o trash can

o mirror

242 Lavatories, urinals and toilet bowls are sufficient and kept clean.

243 Fixtures are in good working condition.

244 Well ventilated.

245 Entrance doors are closed at all times.

246 No faucet leaks.

247 With adequate water supply at all times.

248 Are free from cigarette butts, ashes and stains.

249 In good state of repair. (Note: For food facilities)

250 With disinfectant and hand dryer. (Note: For food facilities)


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Documents

5S Audit Checklist - Shopfloor