5S Lean Manufacturing Audit Checklist

A 5S Lean manufacturing audit checklist is a document contain detailed audit check points through equal combination of 5S and lean manufacturing.

Sort:

Are there any un-need items in the area?

Guidelines: Are there any un-need items in the area (Tools, parts, drawings, paperwork, tables, fixtures, etc)? Pick any object in the area and question a team member. Employee Interview.

Checkpoint:What is it for? How often do you use it? Where is it's home? Need to be Red-tag?

Straighten:

Do the items that are need have a conveniently locate, visually designate homes? When not in use, are they return to their home?

Guidelines:Do items in the area have a designate home? Are they visually (label, color code, shadow boards, etc) and conveniently organize? Can you tell what goes where? .

Checkpoint:What part, tool or paperwork do you spend the most time looking for or walking to while doing your job? Is there a way to decrease that time?

Shine:

Are the machines, work stations, floors, walls and all items in the area clean, free from clutter and properly maintain? Are checklists post and up to date?

Guidelines:Is the entire area clean? Are machines and workstations clean, properly maintain, and have all safety features in place? Do employees understand their role in 5S and TPM (autonomous maintenance)?.

Checkpoint:When is the last time you clean: (pick an item or area) ? How did you know it was time to clean it?

Standardize:

Team has establish and document standards on sort, straighten, and shine (checklist). Are current standards being follow, review and improve upon?

Guidelines: Has the team establish and document procedures for: 5S Checklists, Sort Criteria, Straighten Criteria, Red Tag System, Team Meetings, and Peer audits? Are they following the document procedures? Are the 5S Checklists, Team Binder and visuals organize and up to date?.

Checkpoint:Where is your (name a document) & how do you use it?

Sustain:

Have Sort-Straighten-Shine-Standardize been fully implement and functioning well? Are past audits post and use for improvement?

Guidelines:Are team members continuously improving their area or at least sustaining previous improvements? Were corrective actions taken on low scores from previous audits?.

Checkpoint: Can you point out an improvement made by your team in the last month? How did it come about? How has it help? Could it be improve?

Visual Controls:

Are visual aids in use, up to date and effective in telling how the area is performing, what problems are occurring and what improvements are being made?

Guidelines: Are visual aides in use, up to date and effective in telling how the area is performing? Are their goals, actual performance, reasons for variation, and corrective actions visible, up to date and use as an operational tool?.

Checkpoint: Which visual controls in your area do you use? Why? How often? What do they tell you?

Safety:

Are safe work practices in place and being follow.

Guidelines: Are aisle ways, exits, electrical panels fire extinguishers, MSDS, First Aid, etc clearly mark, free from obstructions and trip hazards. Are chemicals properly store & label? PPE & safe practices use? Emergency procedures known?.

Checkpoint:Emergency procedures known (Tornado Shelters, Fire Procedures, etc), MSDS?

Standard Work:

Do Standard Work and Work Instructions exist for the area? Are they post, in use, follow, understood, and update regularly.

Guidelines: Do Standard Work and Work Instructions exist for the area? Are they post, in use, follow, understood, and update regularly.

Checkpoint:What are your responsibilities, and the best practices for completing the job safely with high quality and efficiency?

Continuous Flow:

Has continuous flow been establish where possible? Does the line move at a steady pace base on Takt? Are standard WIP Levels establish and follow?

Guidelines: Has continuous flow been establish where possible? Does the line (all work stations) move at a steady pace base on Takt? Are standard WIP Levels establish and follow?.

Checkpoint:What is your Takt Time, # of operators and hours work to reach your goal? How does that change when customer demand fluctuates?

Cross training - Job Rotation:

Are employees skill at many different jobs in the area and out. Are these skills document on a skills matrix? Is there a regular job rotation schedule.

Guidelines: Is a cross training and job rotation program in place within the department and other departments? Is the skills matrix utilize effectively to track training and skill levels of employees within and outside the department?.

Checkpoint: How often do you rotate to other jobs? Is training effective-sufficient?

Quality:

Are quality control concepts in place? Is there evidence of defect tracking or other process recording? Are metrics post? Are defects address, not pass on?

Guidelines: Are quality control concepts in place? Is there evidence of Six Sigma, defect tracking, error proofing, root cause analysis or other problem solving? Are results (metrics) post or communicate back to employees? Is there an "Andon" system to respond to problems and discipline to prevent passing on defects?.

Checkpoint: If you discover a defect in your area, what do you do, then what happens? Do defects get pass on?

Material Flow:

Are parts replenish when they are need, where they are need in the quantities need, and present to the operator as need without disruption?

Guidelines: Has a Plan For Every Part (PFEP) been establish? Is it visually obvious how, how many, when, where and by who the parts will be replenishing? Are parts present to the operators where they are need? Can parts be replenish by the materials group without disrupting work?.

Checkpoint: How are your parts replenish? When? By who? What is Kanban and your role in helping it to function properly?

Lean Leadership:

Is a Lean Management system in place that utilizes: 1. Leader Standard Work 2. Visual Controls 3. Daily Accountability 4. Discipline.

Guidelines: Do crew leaders and supervisors for the area demonstrate good Lean Leadership?.

Checkpoint: Do your leaders conduct start up meetings, gemba walks, review visual controls, utilize leader standard work, communicate expectations, hold team accountable and have the discipline to sustain efforts?

Employee Engagement:

Are employees actively participating in continuous improvement efforts (5S team, idea boards, root cause for variation, DLS workshops, update SW, etc..)?

Guidelines: Are employees actively participating in 5S, daily Kaizen, problem solving, DLS Workshops, the Idea Board program or other ways to help their team continuously improve? Is there evidence of recent improvements?.

Checkpoint: What is the most recent improvement made by your team? How has it work? What remains to be done? Were you involve? What is next?

Other Lean Tools

or General Comments? Are there other Lean Concepts, principles or tools have been implement in the area? How have these tools improve performance?

Guidelines: Are there other Lean Concepts, principles or tools implement.

Checkpoint: Are there any examples in your area of using: Set Up Reduction, TPM, Six Sigma, Root Cause Analysis, Value Stream or Process Mapping, Daily Accountability, DLS Workshops (Kaizen), A-3 thinking, Teamwork, Error Proofing, Discipline, Knowledge Share, Kanban, Pull Systems?