Title Page
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Document No. Week
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Title: 5S audit
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Locations/ areas:
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Conducted on :
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Auditors:
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Auditee:
SORT
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1. Is there a 5S notice board in the area, complete with upto date information?<br>1.1 Check for updated on last week audit, action plan, certificate ( if any).<br>1.2 updated team member pictures.<br>1.3 before and after 5s pictures.<br>1.4 Action plan- are the responsibilities allotted to all the team members, check for work distribution.<br>1.5 Action plan related to 5S , AIB, Internal Audit, External and Safety audit.<br>1.6 Question the members on the previous 5s meeting and actions discussed.
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2. Is the areas free from unnecessary items and equipment?<br>2.1 Look out for any irrelevant or unnecessary items in the area.<br>2.2 Are the waste materials disposed off in timely manner.<br>2.3 Are the external area free from unwanted weeds and vegetation.<br>2.4 Are the trash removed on regular basis as per checklist.<br>2.5 Is the tea/coffee vending machine free from spillages or accumulation of dirt.
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3. Is there an upto date action plan on the notice board?<br>3.1 Samples for the action points, responsibility assigned to and closure.Any checklist implementation is a part of action, verify that.<br>3.2 Check whether the previous audit findings are updated in the action plan.
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4. All areas free from clutter and personal belongings?<br>4.1 Clutters are required-items that not organized or arranged appropriately, look for any unorganized tools, stationaries etc.<br>4.2 Are the inside of panel organized.<br>4.3 Are the lockers free from open food materials.<br>4.4 Are the locker room clean with no evident food spillage.
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5. Are all signs and notices up to date, meaningful and in good order?<br>5.1 Check for safety signs- fire extinguisher, push/ pull, PPE, Warning signs at dangerous substances, liquids.<br>5.2 Up to date shift schedules.<br>5.3 Up to date CIP matrix, Coding matrix, Birthday bash info etc.<br>5.4 Bypass of process ,valves, safety doors,sign boards.<br>5.5 Ingredients weighing scoop matrix- colour code.<br>5.6 Signs of fire alarm switch<br>5.7 Save electricity signs at the lamp switch.<br>5.8 Any defective or not working instrument -sign board.<br>5.9 Check for the notice board whether it is updated?<br>5.10 Check whether the location signs are proper and correct.
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6. Are al drawers, cupboards and tables clear from clutter underneath and behind?<br>6.1 Any unwanted tapes, paper piece etc.<br>6.2 Check for dirt accumulation under the electrical panels, cable trays, drip trays, coders etc.<br>6.3 Is the docks/dock levelers underneath is cleaned with no dirts and unwanted materials accumulation.<br>6.4 Catch pans underneath the motors are clean with no accumulation of oil/ grease etc.<br>6.5 Are all the conveyors cleaned on external and underneath.<br>
SET IN ORDER
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7. Are the inside of drawer as and cupboards/ cabinets organised?<br>7.1 Check for dirt accumulation inside the electrical panels, cable trays, drip trays, coders etc.<br>7.2 Is the materials organised and stored in the relevant location mentioned.<br>7.3 Are the materials inside the drawers/ cup boards are labelled and placed in the correct location.7.4 Is there any unwanted nuts/ bolts/ spare parts inside the panel board.<br>7.5 Is the inner surface of filler clean with no evident mold or slime formation.<br>7.6 Is the inner surface of tunnel pasteurizer free from black stains and abundant slime growth.<br>7.7 Is the inner surface of cooling tunnel free of black stains and abundant slime growth.<br>7.8 Are the inner surface of panels clean with no stains or mold growth.<br>7.9 Are the inner surface of cable tray clean with no mold or slime formation,any insects.<br>7.10 Are the drains clean with no accumulation of debris inside.<br>
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8. Are al tools and work items organised?<br>8.1 Shadow board for tools.<br>8.2 Tools organised appropriately,no incorrect labelling.<br>8.3 List of tools maintained.<br>8.4 Is there a record maintained when the tools are issued to other department,updated & verified.<br>8.5 Are the tools replaced back after use.<br>8.6 Uniforms are clean.<br>8.7 Hairnets are worn properly as per standard.<br>8.8 No authorized jewelry or watches .<br>8.9 Is there any damage or crack in glass,plastic or ceramic items in machines.
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9. Are all stock levels controlled, appropriate and visible?<br>9.1 Stock levels are visible where ever its possible.<br>9.2 Does the system and physical stocks match.<br>9.3 If stocks are seen at minimum levels, look for action taken.<br>9.4 For the chemicals used online is there min/ max scale and stock level monitored.
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10. Is all equipment identified and labeled?<br>10.1 Check for identification tag or label for all the instruments.<br>10.2 Check for any spell mistake?
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11. Are locations marked appropriately?<br>11.1 Check for location marking for movable item the naming must be on the area,not on the instrument itself.<br>11.2 Any incorrect or wrong location marking.
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12. Are al documents stored appropriately?<br>12.1 Appropriate document storage- Area is clean ,dry, free from any spillage etc.<br>12.2 File marking standard followed.<br>12.3 Is all team members aware of the standard.<br>12.4 Is the appropriate document stored in the defined area?<br>12.5 Is any other items stored along with the documents like calculator,Personnel files etc.
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13. Can all documents and work items be located in under 10 secs?<br>13.1 Refer the document list/ index and askto retrieve within 10 seconds.<br>13.2 Filler volume adjustment tool, OPC system nozzles,C spanner etc can also be considered as work items.
SHINE
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15. Is appropriate cleaning equipment available and stored correctly?<br>15.1 Shadow boards for cleaning items.<br>15.2 Are all the cleaning materials available.<br>15.3 Colour code matrix for cleaning items are displayed.<br>15.4 Training records are available.<br>15.5 OPL for use of OPC system and cleaning materials.<br>15.6 Are the OPC system working.<br>15.7 Does the OPC system at each area has all the required spares?<br>15.8 MSDS for chemicals used are displayed at point of usage or storage.<br>15.9 Are all the PPE available at the point of use.<br>15.10 Is the colour code followed as per matrix.<br>15.11 Are the spill pallet for OPC system cleaned regularly?<br><br>
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14. Is the area/ machinery free from air/ oil/ water leaks/ ink on floor?<br>14.1 Look for any ,water, air leak at the joints,roofs, AC ducts etc.<br>14.2 Look for any ink/ juice stains on the floor.<br>14.3 Look for any mold growth or stains on the instruments, conveyors etc.<br>14.4 Look for any diesel,oil leakage from forklift machines.<br>14.5 Look for any air leak from air valves, lines, tubes etc.
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16. Have machines and equipments/ working table/ shelves/ cabinets/ tools and equipment cleaned to an appropriate standard?<br>16.1 Are the equipments and machines clean and no visible dirt?<br>16.2 Is there any checklist to verify the cleaning equipments and machines.<br>16.3 Check the condition of eye wash unit.<br>16.4 Are the chemicals in chemical room properly stored (Acid and Base are not mixed).<br>16.5 Are the machine alarm working and not misinterpreting fire safety alarm.<br>16.6 Standard OPL/ SOP for cleaning .<br>16.7 Safety alarm and equipment alarms are not similar, does not create any confusion.<br>16.8 In case of safety, alarm overrides all the other alarms in the factory.<br>16.9 Look for any mold growth or stains on the equipments.<br>16.10 Is the waste disposal containers are cleaned to appropriate standards.l<br>
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17. Are all lights working in the area, no person no light implemented?<br>17.1 No busted lights.<br>17.2 Emergency lights are working.<br>17.3 No person - lights are off.<br>17.4 Check the light lux at different area- are the measured values within the required Food safety standard.<br>17.5 Light covers are present , no cracks covers.
STANDARISE
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18. Are the walls and floors clean and free from dirt/ debris? No pest activity noticed.<br>18.1 Any dirt marks on floor / walls.<br>18.2 Any peeling paint?<br>18.3 Cracked wall/ ceiling?<br>18.4 Verify the bait station, insecticutors, any bird droppings, pest signs etc.<br>18.5 Check for any mold accumulation on the wall and tiles.<br>18.6 Check for any Cobb web on the incoming RM pallets.<br>18.7 Check for dirt/ debris accumulation on the corners of loading bay.<br>18.8 Are the walls, floors in good condition.<br>18.9 Are the drains clean with no accumulation of debris inside.<br>18.10 Are all the door in-good working condition.<br>18.11 Are the doors and windows screened if not in use.<br>18.12 Is there any damage to bait station.<br>18.13 Is there any bird activity noticed inside the factory.<br>18.14 Is there any bird dropping on the floor, walls, racks or on materials stored.
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19. Are all standards and information displayed?<br>19.1 Are the SOPs displayed wherever necessary.Eg: how to use eye washer,fire extinguisher etc.<br>19.2 Standards to be followed inside factory premise.<br>19.3 Information on breakdown maintenance, mnts work in progress.<br>19.4 All PPE available at the location.<br>19.5 Is the entrance to the factory secured.<br>19.6 Is the access to chemical rooms controlled.<br>19.7 Hand washing performed correctly as per procedure.<br>
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20. Is relevant performance data displayed and up to date?<br>20.1 KPI board up to date.<br>20.2 Out of target in RED , and in target with GREEN marking.<br>20.3 Smileys are fixed and visually clear.<br>20.4 Action plan for targets not achieved.<br>20.5 Are the team members aware of the team performance and flaws action taken.<br>20.6 Check for PRAGMA records-preventive maintenance completion and targets.
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21. Are all check list for cleaning and maintenance in place?<br>21.1 High level cleaning checklist .<br>21.2 Cleaning checklist for the particular area.<br>21.3 Equipment calibration checklist.<br>21.4 Previous maintenance plan and records.<br>21.5 Equipments daily maintenance- Coder, Filler, Packer, Forklift, Sweeper machine (Diesel level, battery condition, lights).
SUSTAIN
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22. Has the action plan been updated since last week for 5S, Health & Safety?<br>22.1 Check for 4M boards, 5WHY.<br>22.2 Action plan are update and do reflect the records and improvement.
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23. Has a meeting been held since last week?s<br>23.1 Verify the attendance sheet.<br>23.2 Check with team members about the meeting discussion.<br>23.3 Verify whether all the team members are involved in the meeting.<br>
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24. Is 5S time allocated for all team members?
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25. Are all teams involved in the 5S activities?<br>25.1 Verify the action plan sheet about the responsibilities distribution among the members.
