Empowering Lean Solutions for Everyone

5S Audit

When performing a 5S audit please use a 5S audit check sheet.

Use one check sheet for each area you audit. I hope you remembered to partition your plant and office in 5S areas.

That will be very helpful as you “attack” every opportunity for improvement or non-conformance in each area.

Some helpful hints to get you started with a 5S Audit:

  1. Start your audit by checking items listed on the previous 5S audit – to see if they have been completed (and can be crossed off or not).

This means the best way to improve your score on future audits is to take the current audit and address each item listed.

  1. Do your audit on a regular basis, to ensure that the work everyone has done in implementing the 5S program in the area is maintained over time.
  2. Just walk through the area being audited, looking for the items outlined on the audit checklist. Examples of what is considered unacceptable:
  • Items in the area that are not needed, no longer used, or do not belong in that area (eg. Items from another line, left-over parts from previous builds, etc.).
  • Items that ARE needed in the area but that are not in their designated/labeled spot (have been moved/used and not put away)
  • Items that are needed but do not have a labeled spot (so cannot determine if they are out of place or not) – it includes tools, supplies, WIP, Finished Goods, Suspect parts, etc.
  • Work areas and aisles not clearly indicated – so can’t tell where things can be stored and what areas need to be kept clear.
  • Height/Quantity Limits NOT set/adhered to – meaning proper amounts of items (raw, WIP, finished goods, etc) present, as previously agreed to and labeled (by area size or Qty. labels).
  • Dirt, Oil, Grease, Coolant found on Floors, Walls, Stairs, Work Surfaces, Equipment.

NOTE: Points are NOT deducted if still working in the area and the dirt/oil/grease/coolant is considered part of the process (that will be cleaned up at end of the day).

However, if no longer working in the area, or if an immediate Health & Safety Hazard, the mess needs to be cleaned up before audit is over or points will be deducted.

  1. Measures NOT put in place to prevent area from getting dirty.

This relates to the above dirt/oil/grease/coolant issues, as to whether or not attempts have been made to reduce these and contain them.

The idea is to minimize the amount of hourly or daily cleaning needed by using catch pans (under testers or known leaking machines), by fixing leaks, by mopping floors several times per day, by using shields to deflect material from processing into containers, etc.

  1. Cleaning materials used in the area (Shovels, brooms, mops, dustpans, garbage & cardboard containers, etc.) need to be labeled to show where they belong and be easily accessible where needed.
  2. Labels & Lines need to remain readable/intact – meaning as they wear they need to be fixed or replaced so they remain usable by everyone.
  3. Plant rules not being followed (mostly relates to Safety infractions seen during 5-S audits such as WHMIS label issues, blocked exits/fire equipment, unsafe equipment, etc.). These will be listed on 5-S audit and points deducted.

The supervisor follows up on previous audits noted problems – score is based on whether actions were taken or not to correct previous problems (reflected by number of repeat items found).Forms needed for the 5S Audit:

  • 5S audit check sheet
  • Open issues: list with responsibilities and deadlines

A word of advice: you can write each non-conformity on a suggestion form and pass them on to the department managers.

They can assign people to do the work and also, it would count as them coming up with suggestions for improvement.

It is a great idea to create your own lean suggestion program and recognize and reward your people for their extra effort.