5s & Visual Management Checklist

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

Health and Safety

• Do all processes have a current up to date detailed risk assessment available for inspection

  Yes

  No

  N/A

• Have the emergency stops been tested and has this been recorded ?

  Yes

  No

  N/A

• Is the the processing equipment in a good state of repair

  Safe

  At Risk

  N/A

• Is manual handling an issue for operators?

  Yes

  No

  N/A

• Is the extraction in a good working condition and is it operating as it should do?

  Safe

  At Risk

  N/A

• Are all chemicals handled and stored in the correct manner and location?

  Yes

  No

  N/A

• Is the correct PPE being worn by operators as stated on the process instruction / SOP.

  Yes

  No

  N/A

Workplace organisation

• Is the boundary of each work station clearly defined with floor markings, sign boards ?

  Yes

  No

  N/A

• Areas are defined by colour code I.e. Walk ways, stock locations, work areas, fork lift truck paths?

  Yes

  No

  N/A

• Inventory, tools & equipment is clearly defined I.e. Clear labelling?

  Yes

  No

  N/A

• Locations for tools, cleaning equipment, lubricants, trollys, FLT's are clear shadow boards and floor markings are used?

  Yes

  No

  N/A

• Evidence of inventory control can be seen I.e. Kanban cards, minimum / maximum, first in / first out?

  Yes

  No

  N/A

• There is a numbered system for reporting problems, hazards and maintenance requests and feedback is given within 10 days?

  Yes

  No

  N/A

• Desks, workstations, cupboards and lockers are free of unnecessary paper work & cables?

  Yes

  No

  N/A

• Andon lights are located on key pieces of equipment?

  Yes

  No

  N/A

• There is a mechanism for capturing improvement ideas and implementing / actioning ideas?

  Yes

  No

  N/A

• An improvement board exists in the work areas & a format has been agreed to cover Quality, Cost, Delivery, Safety & Morale?

  Yes

  No

  N/A

• There is evidence of production control I.e. Production management boards.

  Yes

  No

  N/A

• Workers are kept aware of performance to schedule

  Yes

  No

  N/A

• A 5s audit procedure has been agreed I.e. Format and frequency.

  Yes

  No

  N/A

• Documentation is easy to locate?

  Yes

  No

  N/A

• Customer & Company information is displayed?<br>

  Yes

  No

  N/A

• Meeting areas are provided & daily meetings are held?

  Yes

  No

  N/A

• Evidence of regular housekeeping exists and is up to date?

  Yes

  No

  N/A

Standard Operating Procedures & Skills Matrix

• SOPs are displayed in the relevant work areas?

  Yes

  No

  N/A

• SOPs detail process steps, quality, safety issues and include photos ?

  Yes

  No

  N/A

• Work is done according to SOPs?

  Yes

  No

  N/A

• SOPs are used as a tool for continuous improvement?

  Yes

  No

  N/A

• Skills matrixes exist and are regularly updated?

  Yes

  No

  N/A

• Job detail sheets, standard work combination tables are used?

  Yes

  No

  N/A

Quality Control

• Procedures exist for quarantining of reject, rework & scrap?

  Yes

  No

  N/A

• Quality sample boards showing good & bad products exist?

  Yes

  No

  N/A

• Poca yoke (mistake proofing) devices are in evidence?

  Yes

  No

  N/A

• Visual set up indicators are used on all dials and gauges?

  Yes

  No

  N/A

• NRFT results are displayed in the work area?

  Yes

  No

  N/A

Maintenance of equipment

• Maintenance checklists exist and are followed, used and updated.

  Yes

  No

  N/A

• Breakdown, trouble logs exist and are posted in the work area / near the machine?

  Yes

  No

  N/A

• OEE is used this measure performance and results are displayed at the workplace?

  Yes

  No

  N/A

• Daily maintenance is conducted I.e. Lubrication, cleaning, cooling and filter checks are carried out by operators ?

  Yes

  No

  N/A

• Preventative maintenance is completed and records are up to date?

  Yes

  No

  N/A

• Evidence of equipment transparency exists I.e. Transparent gaurding?

  Yes

  No

  N/A

Continuous improvement

• Regular 5s audits are carried out ?

  Yes

  No

  N/A

• Quality, Cost, Delivery, Housekeeping, Safety & Manpower information is easy to read and is up to date?

  Yes

  No

  N/A

• Management deliver team briefs to update operators of business performance?

  Yes

  No

  N/A

• Evidence exists of high levels of continuous improvement? Before and after pictures are displayed?

  Yes

  No

  N/A

• Evidence exists of high levels of continuous improvement?

  Yes

  No

  N/A

• Operational KPIs are displayed in the workplace and are regularly updated?

  Yes

  No

  N/A