Legend not applicable

5 S + S Audit Checklist
Perfect with continuous
Inspection Points Acceptable On going progress visible Unacceptable
Steps Sr. NO improvement

Personal safety equipment list availability and implementation Evidence of PPE usage Some evidence of PPE available
PPEs not clear, not available and not
1 (Hearing, Safety Glasses, Face Shields,Safety Shoes,Proper Uniform, clarty, is available and is but not being used always and not
used
Gloves etc). used clear of PPEs to be used

Hazard conditions-pallets, debris, or sharp objects, trips, spills (water /

Complete compliance to Evidence of no actions taken to
2 oil), Cables are above the ground, not tied together, live ends not hazard requirements
Partial compliance
address the hazard situations
exposed or taped, adequately lighted.

Fire extinguishers, emergency showers, eye wash bottles and Partial compliance(eye wash
Complete compliance to bottles not completely filled,
3 stations where required are present, marked, accessible and requirements checklist s not updated, areas not
No evidence of the controls
checklists are updated (where applicable). marked)

All samples meeting the Evidence of one or more such samples

4 Panels and cabinets are closed and locked. requirement
Partial compliance
not meeting the requirement

Guarding / safety devices or procedures/alarm system/fire hydrand All samples meeting the Evidence of one or more such samples
5 Partial compliance
are in place and effectively used. requirement not meeting the requirement

SAFETY
First aid boxes are
availablein good condition First aid boxes available but either
6 First aid boxes are available, adequately filled and in good condition. and are adequately fille asper not filled or not in good condition
First aidboxes not available
the displayed list

Walkways and emergency exits are free, evacuation routes posted Full compliance to Blocked and no signages posted and
7
and understood. requirements low awareness

Chemicals are correctly labelled, SOP for handling chemicals, MSDS is Full compliance to Evidence of one or more such samples
8 Partial compliance
displayed. Lockout-Tagout procedures are followed. requirements not meeting the requirement

Visible actions on points

Toolbox talks is conducted, improvement points generated and Evidence of tool box talks but no
9 generated through tool box No evidence of tool box talk
effective actions are taken. talks
output generated

Safe work practice (such as using hand rails, safety belts, safe All samples evidenced shows
10 material and equipment handling, using knives towards the body) are full complaince to safe Partial compliance Evidence of unsafe work practice
in place. working behaviour

Evidence that all materials

Evidence of no attempt to evaluate or
available are necessary and Partial compliance
remove unwanted material or usage
being used
All machinery, handling equipment, tools, materials, gages and
11 instrument are necessary and in use

(1S) SORT
Evidence that all storage No attempt to remove unwanted
places are necessary and Partial compliance storage areas and/or blank storage
All storage areas, racks, shelves, cupboards, WIP loations are being used effectively spaces available but not used
12 necessary and are in use.
Red tag are is defined, and
Red tag area defined but either not
used effectively based on
used or materials remain in the
internally agreed procedure No red tag area defined
red tag area for an unreasonable
Red Tag area is identified and in use (frequency / time for doing Red (frequency, responsibility,
amount of time
disposal)
13 Tag Activity is clear and is followed).

Materials and its location is

Materials and its location is
marked and labelled and
All movable equipment, materials, parts and its location is marked arrangement is standard (printed,
14 labelled. coloured, innovative e.t.c)
marked and labelled but
Either materials or its location is
arrangement may be Not at all done, In repeat audits found
marked and /or labelled and is
crudeand not no attempt to be made to do it.
done partially
standard(handmade,
nonstandard tapes e.t.c)

Layout available but may be

Not at all done, In repeat audits found
layout available which is printed, handmade or temporary
no attempt to be made to do it.
Layout of the area is available which shows the location of each item in color and standard arrangement
15 in the area. arrangement
(2S) SET IN ORDER

Area marked and labelled but

may be with handwritten or Some evidence of work in Not at all done, In repeat audits found
temporary arrangement like progress but not completed no attempt to be made to do it.
Interior area of all cupboards and storage locations marked and Area marked and labelled and tapes
16 labelled including contents printed and standard arrangement

All walkways are marked and

All walkways are marked and Not at all done, In repeat audits found
demarcated as per layout but Partial compliance
demarcated as per layout and no attempt to be made to do it.
there may be paint peel off.
17 Corridors and walkways are demarcated and marked paint is clear
Shadow boards available
Shadowboard with outline of tools No shadow boards or place for tools
Tools ( in case of office its stationary) have shadow boards / point of with outline of tools but may Partial compliance
and at point of use and not at point of use
18 use. not be at point of use

All samples evidenced are in Not at all done, In repeat audits found
Partial compliance
Each object/ tool/ material are kept on their marked position compliance no attempt to be made to do it.
19 (practice / behaviour). Yellow line and layout is respected

Free of dust and clean but

All areas shining, clean and Not at all done, In repeat audits found
All floors & Ceiling are free from dust, dirt, debris, inks, oil, parts, with old/ incomplete paint or Partial compliance
painted no attempt to be made to do it.
no paint
hardware, packaging material, walls, windows, ducts, stripcurtains,
20 overhead lamps and fixtures etc are clean.

Free of dust and clean but

All areas shining, clean and The tapes / tape marks directly on the
Equipment (including material handling equipment and tools) and with old/ incomplete paint or Partial compliance
(3S) SHINE

painted equipment
work stations(Area around the machine, behind the machines)is kept no paint
21 clean and free of oil, grease, dust and debris
All areas Free of dust and
All areas shining, clean and Not at all done, In repeat audits found
All storage area (Cupboards,cabinets, WIP storage -racks, pallets) are clean but with old/ Partial compliance
painted no attempt to be made to do it.
22 free of dust, dirt and kept clean. incomplete paint or no paint

All samples evidenced with More samples evidenced with Dirty

Uniform with no stains and perfect
Clean uniforms and shoes as uniforms, shoes, shirts not tugged in,
compliance to hygiene policy
23 People keep themselves clean including uniform, shoes e.t.c per hygiene policy not as per hygiene policy.

Actions taken on abnormilities to Actions are being taken on Evidance of reporting of

Evidence that when cleaning is taking place, the cleaner is looking for No Comments after cleaning
be effectives. reported abnormalities abnormilities post cleaning
24 abnormalities

Schedules are displayed and Schedules are displayed and

Cleaning schedules, frequency and standard method is defined and No schedule exists
followed. partially followed.
25 displayed
(4S) STANDARDIZE

Pictorial sops have been

Sops has been displayed as Some sops against the plan has
displayed which involes min max, No visual display of SOPs
per the plan been done
targets, specifications etc
26 Standard work is defined and visually managed

One or two of the three is

Work environment such as temperature, light intensity (lux), sound Complete compliance No display
complied
level(decibel) should be maintained & displayed with standard and
27 actual values
The graph of the audit & 5S radar is updated. Audit scheduling, audit Compliance to all Only some of requirements are Not at all done, In repeat audits found
28 results (with observation) and action plans are displayed requirement complied no attempt to be made to do it.
Not at all done, In repeat audits found
All areas done as per plan Has a plan and few areas is done
29 Post photographs of the "perfect" setup no attempt to be made to do it.
100% of the persons in the
One or two persons in the
sample(minimum 3) are None of them of aware
sample(minimum 3) are aware
30 All associates are aware on 5S+S. aware
Evidence of sustaining and incremental improvement in audit score
'safety', 'sort', set-in-order', 'shine', 'standardize' (Average scoring for above 80% 60-80 % 40-59% less than 40%
(5S) SUSTAIN

31 previous four consecutive audits)

Less than 30 seconds 30 seconds - 2 minutes Greater than 2 minutes

32 Group can demonstrate retreival of needed items in 30 seconds

Evidence of action taken from previous 5S audit observations. Display and Evidence of internal
Actions taken as per the plan There is a plan with target date No evidence of action taken to improve
brain storming within team and
Rootcauses are eliminated and improvement actions include using 5S to reduce 7 waste
are evidenced and displayed and responsibility 5S audit observations
33 prevention
 Date: Responsible:

Flexible Packaging Country / Plant: Auditor:

5 S + S Audit Checkliste Area / Machine audited:

Perfect with Ongoing

Un-acceptable
Steps No. Inspection points continuous Acceptable (6) progress visible
(0)
Observation / Recommendation Agreed Actions Target date Comment
improvement (9) (3)

Personal safety equipment list availability and implementation (Hearing, Safety

1
Glasses, Face Shields,Safety Shoes,Proper Uniform, Gloves etc).

Hazard conditions-pallets, debris, or sharp objects, trips, spills (water / oil), cables
2 are above the ground, not tied together, live ends not exposed or taped, adequately
lighted.
Fire extinguishers, emergency showers, eye wash bottles and stations where
3 required are present, marked, accessible and checklists are updated (where
applicable).

4 Panels and cabinets are closed and locked.

Guarding / safety devices or procedures / alarm system / fire hydrand are in place
SAFETY

5
and effectively used.

6 First aid boxes are available, adequately filled and in good condition.

7 Walkways and emergency exits are free, evacuation routes posted and understood.

Chemicals are correctly labelled, SOP for handling chemicals, MSDS is displayed.
8
Lockout-Tagout procedures are followed.

Toolbox talks is conducted, improvement points generated and effective actions are
9
taken.

Safe work practice (such as using hand rails, safety belts, safe material and
10
equipment handling, using knives towards the body) are in place.
Make the environment safe - SUBTOTAL 0

All machinery, handling equipment, tools, materials, gages and instrument are
necessary and in use.
11
SORT

All storage areas, racks, shelves, cupboards, WIP loations are necessary and are in
use.
12

Red Tag area is identified and in use (frequency / time for doing Red Tag activity is
clear and is followed).
Remove non-value added items - SUBTOTAL 0

All movable equipment, materials, parts and its location is marked / labelled.
14

Layout of the area is available which shows the location of each item in the area.
SET IN ORDER

15

Interior area of all cupboards and storage locations marked and labelled including
contents
16

Corridors and walkways are demarcated and marked

17

Tools (in case of office its stationary) have shadow boards / point of use.
18

Each object / tool / material are kept on their marked position (practice / behaviour).
Yellow line and layout is respected.
19
Organize, label, assign locations - SUBTOTAL 0
 Date: Responsible:

Flexible Packaging Country / Plant: Auditor:

5 S + S Audit Checkliste Area / Machine audited:

Perfect with Ongoing

Un-acceptable
Steps No. Inspection points continuous Acceptable (6) progress visible
(0)
Observation / Recommendation Agreed Actions Target date Comment
improvement (9) (3)

All floors & ceiling are free from dust, dirt, debris, inks, oil, parts, hardware,
packaging material, walls, windows, ducts, stripcurtains, overhead lamps and
20 fixtures etc are clean.
Equipment (including material handling equipment and tools) and work stations
(area around the machine, behind the machines) is kept clean and free of oil,
21 grease, dust and debris.
SHINE

All storage area (cupboards, cabinets, WIP storage -racks, pallets) are free of dust,
dirt and kept clean.
22

People keep themselves clean including uniform, shoes etc.

23

Evidence that when cleaning is taking place, the cleaner is looking for abnormalities.
24
Clean & healthy work ambience - SUBTOTAL 0

Cleaning schedules, frequency and standard method is defined and displayed.

25
STANDARDIZE

Standard work is defined and visually managed.

26

Work environment such as temperature, light intensity (lux), sound level(decibel)

should be maintained & displayed with standard and actual values.
27

The graph of the audit & 5S radar is updated. Audit scheduling, audit results (with
observation) and action plans are displayed.
28

Post photographs of the "perfect" setup.

29
Visual methods, permanent changes - SUBTOTAL 0

All associates are aware on 5S+S.

30
SUSTAIN

Evidence of sustaining and incremental improvement in audit score 'safety', 'sort',

set-in-order', 'shine', 'standardize' (average scoring for four consecutive audits).
31

Group can demonstrate retreival of needed items in 30 seconds.

32

Evidence of action taken from previous 5S audit observations. Rootcauses are

eliminated and improvement actions include prevention.
33
Training and discipline - SUBTOTAL 0
Total 0

Maximum Score 240

Percentage 0%

5S level 0.0
 xx.yy.2014
Steps Sr. NO Inspection Points 1. Audit
1 Personal safety equipment list availability and
2 implementation (Hearing, Safety
Hazard conditions-pallets, debris,Glasses,
or sharpFace
3 Shields,Safety
objects,
Fire extinguishers, Shoes,Proper
trips, spills emergency Uniform,
CablesGloves
(water / oil),showers, are
eye above
4 etc).
the
wash ground,
Panelsbottles not tied
and stations
and cabinets together, live
whereand
are closed ends
requirednot
locked.are
SAFETY

5 exposed
present, or taped,
marked, adequately
accessible
Guarding / safety devices or procedures/alarmandlighted.
checklists are
6 updated
system/fire (where
First aid boxes hydrandapplicable).
are in place
are available, and effectively
adequately filled and
7 used.
in good condition.
Walkways and emergency exits are free,
8 evacuation are
Chemicals routes postedlabelled,
correctly and understood.
SOP for
9 handling
Toolbox talks is conducted, improvementLockout-
chemicals, MSDS is displayed. points
10 Tagout
generated
Safe
All procedures
and
work practice
machinery, effective
handling are followed.
actions
(suchequipment, are
as using hand taken.
rails,
tools,
safety belts,
materials, safeSumme
gages material
and and equipment
instrument are necessary
11 handling,
and in use
All storage
Red Tag using isknives
areas,
area racks,
identified towards
and inthe
shelves, body)
cupboards,
use are in
(frequency WIP/
SORT

place.
(1S)

12 loations are necessary and are

time for doing Red Tag Activity is clear and is in use.
13 followed).
All movable equipment, Summe materials, parts and its
14 location is marked
Layout of the area is labelled.
available which shows the
(2S) SET IN

15 location of each item

Interior area of all cupboards in the area. and storage
ORDER

16 locations marked
Corridors and walkwaysand labelled including contents
are demarcated and
17 marked
Tools
Each (object/
in casetool/of office
material its stationary)
are kept onhave their
18 shadow
marked boards
All floorsposition
& Ceiling/ point
(practice of use.
are free/ behaviour).
from dust, dirt, Yellow line
debris,
19 and layout
Equipment is
inks, oil, parts, respected
hardware,
(including packaging
material handling material,
equipment
walls, windows, ducts,
Summe stripcurtains,
and tools) and work stations(Area around the overhead
20 lamps
machine, andbehind
All storage fixtures theetcmachines)is
are clean. kept clean
area (Cupboards,cabinets, WIP and
(3S) SHINE

21 free of oil, grease, dust and debris

storage -racks, pallets) are free of dust, dirt and
22 kept
People clean.
keep themselves clean including uniform,
23 shoes e.t.cthat when cleaning is taking place, the
Evidence
24 cleaner is looking for abnormalities
Cleaning schedules,
Work environment Summe frequency
such and standard
as temperature, light
25 method is defined and displayed
intensity (lux), sound level(decibel) should be
STANDARDI

26 Standard
The graphwork
maintained is audit
of& the defined
displayed &with andradar
5S visually
standard managed
and actual
is updated.
(4S)

27 valuesscheduling, audit results (with observation)

ZE

Audit
28 and action plans are displayed
29 Post photographs
Evidence of sustainingof theand "perfect"
incrementalsetup
improvement in Summe
audit score 'safety', 'sort', set-in-
30 All associates
order', 'shine', are aware on(Average
'standardize' 5S+S. scoring for
SUSTAIN

31 four consecutive
Evidence audits)
Group canofdemonstrate
action takenretreival of needed
from previous items
5S audit
(5S)

32 in 30 seconds
observations. Rootcauses are eliminated and
33 improvement actions include prevention
Summe
Total 0
Maximum Score 240
Percentage 0%
Target 40%
5S level 0.0
xx.yy.2014 xx.yy.2014 xx.yy.2014 xx.yy.2014 xx.yy.2014
2. Audit 3. Audit 4. Audit 5. Audit 6. Audit

0 0 0 0 0
240 240 240 240 240
0% 0% 0% 0% 0%
60% 80% 90% 90% 90%
0.0 0.0 0.0 0.0 0.0
100%
Result Target

90%
90% 90% 90%

80%
80%

70%

60%
60%

50%

40%
40%

30%

20%

10%

0% 0% 0% 0% 0% 0%
0%
xx.yy.2014 xx.yy.2014 xx.yy.2014 xx.yy.2014 xx.yy.2014 xx.yy.2014