Date:_____________________

5S Workplace Checklist
Level 1 Little Conformance Level 0 No conformance

Rating Level
Level 3 Mostly in Conformance Level 2 50/50 Conformance Level 4 Full Conformance 4 Level 5 Conformance and Safe 5 5 5 5 5 5

Work Area: Auditor:

Facility: Total =
#1 SORT When in doubt sort it out!! 8

#1 Score 0 1 2 3

Distinguish between the needed and not needed. Excess/unneeded equipment, containers, tools removed from area
Corners, walkways, aisles etc. free from blockages and material Trip hazards and obstructions eliminated from area Unnecessary parts, materials, inventory removed from area Are obselete/unneeded labels etc. on walls equipments boards etc.

Auditor comments:

#2 Score 0 0 1 1 2 2 3 3 4 5 4

#2 Set in Order A place for everything and everything in its place! Organize the cell for easy access and identification.
Are all work area boundaries clearly marked Are storage places for all work in progress designated and marked Are storage places for tools and equipment designated and marked Are machines and items labelled as they should be Are all cables, lines, controls and gauges identified and labelled.

Auditor comments:

#3 Score 0 0 1 1 2 2 3 3 4 5 4

#3 SHINE Inspection through cleaning!! To remove all dirt, grime, dust, garbage, etc. from cell.
Is the area free from general rubbish and dirt Are signs, labels, lines, clean, clear and easy to see Are the floor, walls, parts, machinery free from all foreign material Are sources of dust, dirt, spills and foreign material under control Are there any other cleaning problems of any kind present

Auditor comments:

#4 Score 0 0 1 1 2 2 3 3 4 5 4

#4 STANDARDIZE Everything in a state of readiness!! Form a daily habit and prevent setbacks of the first 3 S's. Maintain and monitor #1 through #3
Are cleaning and checking schedules available and in documented use Are all bins, parts, machinery properly identified and labelled Are up to date work instructions, forms, travellers available and in use Are all items required for procedures readily available in location Are any required safety checks being carried out and documented

Auditor comments:

#5 Score 0 0 1 1 2 2 3 3 4 5 4

#5 SUSTAIN Training reinforcement & measurement. Maintain discipline through systems and a supportive culture. Always follow Standard Procedures and Standard Work. Is there a plan for sustaining the first 4 S's?
Are all unused parts tools, equipment properly stored and free from dirt Are all materials and work in progress labelled as such and properly stored Are all personnel fully trained in the tasks they are responsible for Regular auditing to verify compliance with production & safety systems

Auditor comments:

#6 Score 0 0 1 1 2 2 3 3 4 5 4

#6 SAFETY Look over every aspect of the cell and the methods used to make the product. Be sure ALL aspects are being done in a safe manner. Please keep in mind housekeeping is a safety issue. Make sure ALL work areas and conditions are safe. Safety information is displayed and up to date. Daily inspection sheet is posted and up to date. Employees wearing proper PPE. Any safety concerns that haven't been addressed. Is monthly safety training being given to employees.

Auditor comments:

Best score possible = 30
AJD 08 Dec 2008

AJD 08 Dec 2008 .

AJD 08 Dec 2008 .

Potential Failure Mode Potential Effect(s) of Failure S e v Requirements C l a s s Potential Cause(s)/ Mechanism(s) of Failure O c c u r Current Process Current Process Controls Controls Prevention Detection D e t e c R P N Recommende d Actions D e t R P N AJD 08 Dec 2008 .) Rev Core Team Process Function Action Results Responsibility & Target S O Completion Actions Taken e c Date v c N o .Confidential Item Process Responsibility Model Year(s)/ Vehicles (s) Key Date FMEA Number Prepared By FMEA Date (Orig.

Potential Failure Mode Potential Effect(s) of Failure S e v Requirements C l a s s Potential Cause(s)/ Mechanism(s) of Failure O c c u r Current Process Current Process Controls Controls Prevention Detection D e t e c R P N Recommende d Actions D e t R P N AJD 08 Dec 2008 .FMEA Number Confidential Item Process Responsibility Prepared By Model Year(s)/ Vehicles (s) Key Date FMEA Date (Orig.) Rev Core Team Process Function Action Results Responsibility & Target S O Completion c Actions Taken e Date v c N o .

Manufacturing Product/Process Methods Evaluation Measuring Spec. Tools for No. Control Method Reaction Plan Product Process SC AJD 08 Dec 2008 ./Tolerance Technique Sample Size Freq.) Date (Rev. Jig.Prototype Planning Production Core Team: Control Plan Number: Part Number / Latest Change Level: Part Name / Description: Supplier / Plant / Code Confidential Date (Orig.) Customer Engineering Approval / Date (If Req'd): Customer Quality Approval / Date (If Req'd): Other Approval / Date (If Req'd): Supplier / Plant Approval / Date: Other Approval/Date (If Req'd): Characteristics Part / Process Number Part / Process Name Machine. Device.

Action Status 0 0 0 Authors: Revision No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Action Status Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Program Category Responsible Completion Date Days Rem. Product Code: Product Name: Current Status: Plant: Customer: Priority No.: Key contacts: Date(orig) Revision Date: AJD 08 Dec 2008 .CONTINUOUS IMPROVEMENT PLAN Control Plan No.

: Key contacts: Date(orig) Revision Date: AJD 08 Dec 2008 . Product Code: Product Name: Current Status: Plant: Customer: Priority No.CONTINUOUS IMPROVEMENT PLAN Control Plan No. 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 Action Status Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Program Category Responsible Completion Date Days Rem. Action Status 0 0 0 Authors: Revision No.

Product Code: Product Name: Current Status: Plant: Customer: Priority No. 103 104 105 106 107 108 Action Status Incomplete Incomplete Incomplete Incomplete Incomplete Incomplete Program Category Responsible Completion Date Days Rem.: Key contacts: Date(orig) Revision Date: AJD 08 Dec 2008 . Action Status 0 0 0 Authors: Revision No.CONTINUOUS IMPROVEMENT PLAN Control Plan No.

0 AJD 08 Dec 2008 .

0 AJD 08 Dec 2008 .

0 AJD 08 Dec 2008 .

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