Checklist: 5S Audit for Factory Areas
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5S AUDIT CHECKLIST FOR FACTORY AREAS
Furniture & Equipment – Are work benches, carts, machines, equipment, cabinets, tool boxes, shelves,fixtures, structures or areas which collect clutter free of unnecessary items?
PPE – Are all safety gloves, armguards, safety glasses, ear plugs, aprons, etc. in area necessary?
Documents – Are unauthorized/outdated instructions, visual aids, inspection forms, work instructions etc removed from the work area?
Floor & Walk Aisles – Are floors & workstation surfaces free of unnecessary hardware, parts, papers, cardboard, metal, pens, debris, trash etc.?
Cleaning Equipment – Is all cleaning equipment & supplies such as rags, mops, mop buckets, brooms, dust pans, cleaning solutions, floor mats etc.in area necessary?
Tools, fixtures, gages, hand tools – Are only necessary tools needed to perform the workstation job tools, fixtures, gauges, air wrenches, hand tools etc. – located in the area?
Part Containers – Are only necessary part containers such as colored totes, wire baskets, tote pans, returnable totes or containers located in the area?
Personal items – Have all personal items such as lunch boxes, coats/sweat shirts, newspapers, food, magazines – been removed from the work area?
Has all trash, scrap, rework and their containers been removed from the area?
Inventory and Work In Process WIP – Is the area free of excess inventory & parts? Parts in excess of min/max levels or specified limits. Have excess containers or shelves to hold excess inventory?
Furniture & Equip – Are tables, containers, bins, parts, racks, carts, cabinets, tool boxes, shelves, structures foot printed and labeled?
Personal Protective Equipment – Is emergency equipment easily identified at a glance and arranged for ease of access? Are E-stops easily identified and positioned so team members can quickly access them? Is all emergency equipment labeled and in the de
Are emergency exits, first-aid, electrical panels and hazardous materials appropriately identified/labeled and accessible?
Documentation – Are visual aids, inspection instructions, work instructions, 5S checklist etc. in a designated labeled location?
Floor & Walk Aisles – Are floors and walk aisles clearly foot printed and labeled using proper color guidelines?
Cleaning Equipment – Are rags, mops, mop buckets, brooms, dust pans, cleaning solutions,etc. labeled and footprinted and in the designated location?
Tools, fixtures, gages, hand tools – Are tools, fixtures, tuggers, fixtures, gauges, air wrenches etc. footprinted/labeled and in designated location?
Part Containers – Are part containers such as colored totes, wire baskets, tote pans, returnable totes or containers labeled with part names and numbers? Is shelving that part containers sit on labeled to match part container?
Personal items – Are personal items such as beverages in designated and labeled location?
Inventory and WIP – Are standard WIP levels indicated at work station with label or by right sizing of container and are inventory levels marked by min/max indicators where applicable?
Work Stations – Are all items on work stations in proper location and are they clean? Personal Protective Equipment PPE – , WIP containers, tools, floors, desk, carts, fixtures rework areas etc. –
Machines, Equipment & Tooling – Are all equipment, work benches, tuggers, baskets, bins, totes etc. clean and in their designated location?
On-line Production Material, Supplies & Parts Storage – Are all on-line production materials, supplies and part containers etc. clean and in their designated location?
Tool Boards – Are all tools etc. in the designated location on the tool boards and all tools & tool boards clean?
Off-Line Storage – Are all items on racks, dies, carts fixtures, floors etc. in off-line storage areas clean and in their designated locations?
On-Line Cabinets, Shelving – Are cabinets, files clean and in their designated location?
Inventory Storage Areas such as staging areas, material holding areas and quality defect holding areas – Are inventory storage areas such as staging areas, material holding areas and quality defect holding areas/items clean and in their designated location
Information – Is all posted information on performance boards, communication boards, clean and in the right location?
Pull System – Are all items in super markets/grocery stores in proper place and are their procedures in place to replenish the system?
Safety and Quality Related Controls – Have visual aids for appropriate safety and quality concerns been documented visually?
Work Surfaces, Work Stations, Sub Stations and Floors – Have ideas or devices been installed to prevent work surfaces, work stations, sub stations and floors from becoming unorganized, messy or dirty?
Machines, Equipment, Furniture, Tooling etc. – Have ideas or devices been installed to prevent machines, equipment, furniture, tooling etc. from becoming unorganized, messy or dirty?
Inventories & WIP areas – Have ideas or devices been installed to prevent on-line and off-line inventories & WIP areas from becoming unorganized, messy or dirty?
Tool Boards, Shelving & Cabinets – Have ideas or devices been implemented to prevent these areas from becoming unorganized messy or dirty?
Personal Items – Have ideas or devices been implemented to prevent these areas from becoming unorganized messy or dirty?
Have 5S audits been completed per weekly for 3 straight months?
Have posted countermeasures been completed on time?
Visual control – Can all unnecessary items can be distinguished at a glance?
Can all employees clearly articulate the 5S objectives of the area?
Are there any other areas that need attention?
Prepared by:Prev chapter: Kicking Off Your Continuous Improvement Program
Next chapter: Checklist: 6S Lean Manufacturing Walk