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Audit Team: Refer to details below for explanation of each question. If further clarification or examples are
needed ask supervisors or lean coordinator. The audit is a too for improvement so include clear comments and
conduct employee interviews to understand what has been done and why.
Comments: Include specific gaps, exceptional and below standard examples as well as ideas for improvement.
Employee Interview (EI): Interview an employee or two from the area to better understand how Lean & 5S are
working in the area. (You do not need to ask all questions, just when you need to get a better understanding of
where they are.)
Audited Team: Corrective Action should be taken for scores of 0 or 1. Consider all suggestions and ideas.
1. Sort 2. Straighten 3. Shine
Do items in the area have a designated home? Are Is the entire area clean? Are machines and
Are there any un-needed items in the area they visually (labeled, color coded, shadow boards, workstations clean, properly maintained, and
(Tools, parts, drawings, paperwork, tables, etc) and conveniently organized? Can you tell have all safety features in place? Do employees
fixtures, etc)? Pick any object in the area and what goes where? EI: What part, tool or understand their role in 5S and TPM (autonomous
question a team member. Employee Interview paperwork do you spend the most time looking for maintenance)? EI: When is the last time you
(EI): What is it for? How often do you use it? or walking to while doing your job? Is there a way cleaned: (pick an item or area) ? How did you
Where is it's home? Need to be Red-tagged? to decrease that time? know it was time to clean it?
Are quality control concepts in place? Is there Has a Plan For Every Part (PFEP) been
evidence of Six Sigma, defect tracking, error established? Is it visually obvious how, how
Is a cross training and job rotation program in proofing, root cause analysis or other problem many, when, where and by who the parts will be
place within the department and other solving? Are results (metrics) posted or replenishing? Are parts presented to the
departments? Is the skills matrix utilized communicated back to employees? Is there an operators where they are needed? Can parts be
effectively to track training and skill levels of "Andon" system to respond to problems and replenished by the materials group without
employees within and outside the department? discipline to prevent passing on defects? EI. If you disrupting work? EI: How are your parts
EI: How often do you rotate to other jobs? Is discover a defect in your area, what do you do, replenished? When? By who? What is Kanban
training effective-sufficient? then what happens? Do defects get passed on? and your role in helping it to function properly?
13. Lean Leadership 14. Employee Engagement 15. Other Lean Tools
Are employees actively participating in 5S, daily Are there other Lean Concepts, principles or tools
Do crew leaders and supervisors for the area Kaizen, problem solving, DLS Workshops, the Idea implemented. EI: Are there any examples in your
demonstrate good Lean Leadership? EI. Do your Board program or other ways to help their team area of using: Set Up Reduction, TPM, Six Sigma,
leaders conduct start up meetings, gemba walks, continuously improve? Is there evidence of recent Root Cause Analysis, Value Stream or Process
review visual controls, utilize leader standard improvements? EI: What is the most recent Mapping, Daily Accountability, DLS Workshops
work, communicate expectations, hold team improvement made by your team? How has it (Kaizen), A-3 thinking, Teamwork, Error Proofing,
Do crew leaders and supervisors for the area Kaizen, problem solving, DLS Workshops, the Idea implemented. EI: Are there any examples in your
demonstrate good Lean Leadership? EI. Do your Board program or other ways to help their team area of using: Set Up Reduction, TPM, Six Sigma,
leaders conduct start up meetings, gemba walks, continuously improve? Is there evidence of recent Root Cause Analysis, Value Stream or Process
review visual controls, utilize leader standard improvements? EI: What is the most recent Mapping, Daily Accountability, DLS Workshops
work, communicate expectations, hold team improvement made by your team? How has it (Kaizen), A-3 thinking, Teamwork, Error Proofing,
accountable and have the discipline to sustain worked? What remains to be done? Were you Discipline, Knowledge Share, Kanban, Pull
efforts? involved? What is next? Systems?