5 S Checklist - Workplace Evaluation

Date:

# of problems 5 or more 3 to 4 2 1 None Score 1 2

Score 0 1 2 3 4 3

Category

Item Distinguish between what is needed and not needed Unneeded equipment, tools, furniture, etc. are present

Sort

Unneeded items are on walls, bulletin boards, etc. Items are present in aisleways, stairways, corners, etc.

( Organization )

Unneeded inventory, supplies, parts, or materials are present Safety hazards ( water, oil, chemicals, machines ) exist A place for everything and everything in its place Correct places for items are not obvious

Set in Order

Items are not in there correct places Aisleways, workstations, equipment locations are not indicated

( Orderliness )

Items are not put away immediately after use Height and quantity limits are not obviuos Cleaning, and looking for ways to keep it clean and organized Floors, walls, stairs, and surfaces are not free of dirt, oil and grease

Shine

Equipment is not kept clean and free of dirt, oil, and grease Cleaning materials are not easily accessible

( Cleanliness )

Lines, labels, signs, etc. are not clean and unbroken Other cleaning problems ( of any kind ) are present Maintain and monitor the first three catagories Necessary information is not available

Standardize

All standards are not known and visible Checklists don't exist for all cleaning and maintenance jobs

( Adherence )

All quantities and limits are not easily recognizable How many items can't be located in 30 seconds Stick to the rules How many workers have not had 5'S training

Sustain

How many times, last week, was daily 5'S not performed How many times that personal belongings are not neatly stored

( Self-discipline )

Number of times job aids are not available or up to date Number of times, last week, daily 5'S inspections were not performed Total

Manufacturing Area 5S Evaluation Checksheet

Work Area:
0
Unacceptable No evidence of this item

Score for week ending ________________

Assessor:
1
Activity started Slight evidence of this item

2
Widespread activity Many opportunities for improvement

3
Minimum acceptable level sustained for at least one month

4
Very good results sustained for at least three months

5
World class example sustained for at least six months

Item and Description 1S: Separate/Sort

1. First impression overall

Application
Your general impression should tell you this is the best you have seen for a factory. All items not necessary for performing work are removed from the workplace. Only tools and product are present at the workstations. No outdated, torn, or soiled announcements are displayed. All bulletins are arranged in a straight and neat manner. Items are arranged, divided, and clearly labeled such that it is obvious where things are stored and where they should be returned. WIP, tools, materials, and products are not left to sit directly on the floor. Large items are positioned on the floor in clearly marked areas. Storage of boxes, containers, and material is always neat and placed at right angles. When items are stacked, they are aligned and not in danger of falling over.

Score

Opportunities for Improvements

By Whom

When

2. Removing unnecessary items

3. Bulletin boards

2S: Straighten
1. Shelves, benches, and desks arranged

2. Items on floor

3. General storage and arrangement

Item and Description

4. Equipment: Cleanliness and Organization 5. Unobstructed aisles and access

Application
Nothing is placed on top of machines, cabinets, and equipment. Nothing leans against walls or columns. Aisles are free of material and obstructions. Nothing is on the lines and objects are placed at right angles to the aisles. Fire hoses, extinguishers, and other emergency equipment are unobstructed and stored in an obvious, easy to locate manner. Safety devices are clearly marked and highly visible. Aisles and walkways are clearly delineated and can be identified at a glance. Lines are straight and at right

Score

Opportunities for Improvements

By Whom

When

6. Emergency access

7. Aisle markings

access

6. Emergency access

7. Aisle markings

8. Document storage

9. Tools and gages: arrangement

10. Equipment: maintenance

11. Shelves, toolboxes, benches, and desks: control

obstructions. Nothing is on the lines and objects are placed at right angles to the aisles. Fire hoses, extinguishers, and other emergency equipment are unobstructed and stored in an obvious, easy to locate manner. Safety devices are clearly marked and highly visible. Aisles and walkways are clearly delineated and can be identified at a glance. Lines are straight and at right angles, with no chipped or soiled paint. Only documents necessary to do the work are stored at workstations. Documents and binders are stored in a neat and orderly manner. Tools, fixtures, and gages are arranged neatly and stored in a way that they are kept clean and free of any risk of damage. Controls for machines are properly labeled. Critical points for daily maintenance checks are clearly marked. Checklists are neatly displayed and kept clean and updated. These are kept free of unused objects, including files and documents. Tools and fixtures are stored in dedicated shadow boxes or hanging and are cleaned before being returned to proper position after use.

Item and Description 3S: Scrub/Shine

1.Floor cleaning

Application
All floors are clean and free of debris, oil, and dirt. Cleaning of floors is done routinely, daily at a minimum. All machines and equipment are painted and look clean. There are no places in the area less than six feet high (or two meters) that are unpainted and clean. Machines and equipment are constantly kept clean and unsoiled. Routine daily care keeps work surfaces and the general area clean and polished. Guards and deflectors are used to keep chips and waste from falling on floor. All cleaning equipment is stored in a neat manner. It is obvious where it belongs and is easily available when needed. Hazardous materials and containers are properly labeled. Display boards are present in each work area and are within sight of all operators in the area. 5S audits are done in each work area at least monthly with the results

Score

Opportunities for Improvements

By Whom

When

2. Equipment: painting

3. Equipment: cleanliness

4. Storage of cleaning equipment and supplies

4S: Standardize
1. Visual control

2. Monthly audits

equipment and supplies

neat manner. It is obvious where it belongs and is easily available when needed. Hazardous materials and containers are properly labeled. Display boards are present in each work area and are within sight of all operators in the area. 5S audits are done in each work area at least monthly with the results recorded and posted on the cell activity board. Action plans are clearly posted and updated showing responsible parties for completing action items.

4S: Standardize
1. Visual control

2. Monthly audits

3. Action plan

Item and Description 5S: Sustain

1. Document control

Application
All documents are labeled as to contents. Obsolete or unused documents are routinely purged. This includes files as well as computer file storage. There is a disciplined system of control and maintenance to assure that each of the above items is maintained at the highest possible level. The responsible plant manager / staff person should visit each work area at least monthly and initial/ date the 5S audit checklist.

Score

Opportunities for Improvements

By Whom

When

2. 5S control and sustaining

3.Work area visits

Total:

24

New 5S Score

5S Manufacturing Evaluation
5 Points
World Class
Separate/Sort Every item in the area is needed and up-to-date. Consider: - Supplies - Tools - Equipment - Furniture - Documents - Bulletin board postings Area very well organized. Excellent visual controls are in place. There is a designated or labeled location for all items. Locations are convenient and items are stored properly. Equipment and aisles have designated markings

Week of ___/____/____ Assessor: __________________

Area or Zone:________________________

For each S, Circle the block which comes closest to describing the area being assessed.

4 Points
Very Good
Minimal clutter, but a small amount of unneeded supplies, tools, equipment, furniture, documents or general items.

3 Points
Minimum Acceptable
The area has some clutter and unneeded items. Some items stored on top of cabinets. Some needed items are not available or on order.

2 Points
Marginal
More clutter and unnecessary equipment. There is no unneeded furniture or equipment, but desks, shelves and cabinets have excess items. Area moderately organized. Many key items have a designated location, but some do not, and some items are improperly stored. Equipment and aisles may not be clearly marked. Although some visual controls are in place, many more could be added.

1 Point
Unacceptable
Generally cluttered. Quite a few unnecessary items either on benches, desks, shelves or cabinets. Some unneeded furniture and equipment. Items stored on floor. Inadequate organization. Many key items have no designated location. Shelves and drawers are poorly labeled. Aisles or equipment markings are not clear or straight. Very few visual controls or instructions are evident. Safety equipment is not designated. Area needs to be picked up. Items have not been cleaned in some time. Significant oil leakage. Floor is dirty and/or waste containers are full.

0 Points
Poor
Station is cluttered/unsafe. Many unnecessary items everywhere. Much unneeded furniture, & equipment. Emergency equipment blocked. Poor organization. Little indication for a designated place for anything. Items improperly stored on the floor and benches. Trip hazards. Furniture and tools located far from where needed. No current visual controls, signs or labels.

Straighten

Scrub/Shine

Everything in the area is in like new condition. Oil socks are not required. No dust or dirt anywhere. Floors shine.

Area well organized. Most moveable items have a designated location. Although not perfect, most locations are good, and items are stored properly. Equipment, tooling & related supplies are co-located & orderly. Many visual controls are in place. Aisles are neat & clear. Everything in the area is clean and functional. Oil socks are not needed. Floors are clean, and baskets are emptied daily.

Area well organized. With the exception of a few problems, most items have a designated appropriate location, and most tools, documents & supplies are stored properly. All aisles are marked, but some moveable equipment is not. Many visual controls are in place.

Standardize

Sustain

A 5S checklist is posted in the area and it is clearly followed everyday. All required PMs have been performed. All metrics and charts in the area are current. It is clear that follow-up actions to identified problems have been done. There is a clearly documented and followed system to maintain 5S.

A 5S checklist is posted and seems to be followed. All required PMs have been performed. All metrics and charts in the area are current. It is clear that follow-up actions to identified problems have been done. There is a system in the area and strong interest in maintaining 5S.

Most items in the area are clean and functional. Oil socks are neat. Some equipment malfunction or needs painting. Floors are pretty clean and baskets are emptied daily. Although a 5S checklist is not posted, it is available. All required PMs have been performed. All metrics and charts in the area are current. It is somewhat clear that follow-up actions to identified problems have been done. There is a system in the area and moderate interest in maintaining 5S.

There is some clutter. Some items are not clean and/or swept. Some oil leakage in pan. Floors and/or waste containers are marginal.

Although a 5S checklist is not posted, it is available. All required PMs have been performed. Metrics and charts in the area are not current. It is unclear that follow-up actions to identified problems have been done. There is a system in the area and spotty interest in maintaining 5S.

There is no evidence that a 5S checklist exists for the area. All required PMs have been performed. Metrics and charts in the area are not current.

Area is very dirty. Furniture, equipment, shelves, fixtures, and tools area coated with dirt and/or oil. Possible health and safety hazards exist, such as trip hazards, or obstructed emergency items or exits. There is no evidence that a 5S Checklist exists for the area. PM log is not up to date. Metrics and charts in the area are not current.

There is no system in the area and little interest in maintaining 5S.

There is no system or commitment within the organization to sustaining 5S.

# # # # #

of of of of of

5s 4s 3s 2s 1s

circled: circled: circled: circled: circled:

____ ____ ____ ____

X X X X

5 4 3 2

= = = =

______ ______ ______ ______ ______ ______ 5 =

Opportunities for Improvement:

5S Rating

Who

When

Total: