Inspection Page

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AM Checksheet

1. GROUP ACTIVITY

  • 1.1) Have the leaders and members being trained on AM Step 1-3 and SHE awareness?

    - Training records.
    - Inclusion of Safety, Health and Environment aspect.
    - Assessment through interview and genba.
    - Satisfactory explanation on activities.

    Definition:
    1- None.
    2- Only the leader was trained.
    3- All were trained.
    4- All were trained and leaders can be trainers
    5-All were trained and all can be trainers.

  • 1.2) Is the AM activity adequate to ensure machine and surrounding area are in good condition?
    Sub Criteria 1:
    - Sufficient time for allocation activity.

    Definition:
    1- No time allocation for AM activity.
    2- AM activity time allocation not sufficient.
    3- AM activity time allocation is sufficient but activity was not done consistently.
    4- AM activity time allocation is sufficient and activity was done consistently.
    5- AM activity time allocation is sufficient and activity was done consistently.

  • Sub Criteria 2:
    - AM Daily checklist

    Definition:
    0- Daily checklist not available
    2- Daily checklist is available but not updated.
    3- Daily checklist is available and updated.
    4- Major finding(s) on daily checklist item(s)
    5- Minor finding(s) on daily checklist item(s)

  • 1.3) Is there evidence of fuguai detection being carried out on regular basis to support AM activities?
    Document:
    - Fuguais (Blue and red)
    - Fuguais current status (detected, restored, pending).

    Definition:
    1- None
    2- Fuguai detection was done occasionally.
    3- Fuguai detection was done frequently by executive(s).
    4- Fuguai detection was done frequently by group leader(s).
    5- Fuguai detection was done frequently by group leader(s) and some members.

  • 1.4) Do the teams actively carry out fuguai restoration?
    Sub Crieria 1:
    - Fuguai summary

    Definition:
    1- Very minimum fuguais were restored. No revised date observed for others.
    2- Some fuguais were restored. Many revised date observed for other fuguais.
    3- Some fuguais were restored. No revised date observed.
    4- All fuguais are restored but the effectiveness are still under observations.
    5- All fuguais are restored timely and effectively.\

  • Sub Criteria 2:
    - Fuguai detected, restored and pending status available.
    - Fuguai mapping - pending fuguais with evidence of actions taken.

    Definition:
    0- Fuguai mapping not available.
    4- Fuguai mapping is available with action taken on pending fuguai.
    5- Fuguai mapping is available and some pending items were solved.

  • 1.5) Is there a group display board where group AM activities and KPIs are being displayed clearly?
    Sub Criteria 1:
    Display Boards and material/document displayed:
    - Organization (include maintenance).
    - Zoning ownership
    - Activity schedule (Building maintenance activities available in Master Plan eg. floor maintenance, wall maintenance and ceiling maintenance.)
    - Fuguais/Before-After (Blue and Red).
    - AM/5S standards - control rules.

    Definition:
    1- None
    2- Available, but not updated. Many information not complete.
    3- Available but partially updated. Some information were not complete..
    4- Available, information are complete and all are updated.
    5- Available, information are complete and all are updated.

  • Sub Criteria 2:
    - Kaizen activities.

    Definition:
    2- No kaizen activity.
    3- Less than 3 kaizen activities with cost savings implemented.
    4- More than 3 kaizen activities with cost savings implemented.
    5- More than 5 kaizen activities with cost savings implemented.

2. 3S

  • 2.1) Is 1S being practiced and maintained?
    Sub-Criteria 1:
    Non-compliances include :
    - Unneeded items.

    Definition:
    1- 4 non-compliances or more per macro zone whereby unneeded or misplaced items are found.
    2- 3 non-compliances per macro zone whereby unneeded or misplaced items are found.
    3- 2 non-compliances per macro zone whereby unneeded or misplaced item is found.
    4- 1 non-compliance per macro zone whereby unneeded or misplaced item is found.
    5- No unneeded or misplaced items found except those at red tag area(s).

  • Sub-Criteria 2:
    Options available :
    - Centralized or multiple tag by zones.
    - Red Tag flow chart is to be approved.

    Definition:
    1- 5S Red tag area(s) is(are) available.
    2- 5S Red tag area(s) is(are) available.
    3- 5S Red tag area(s) is(are)available and all red tag items are tagged.
    4- 5S Red tag area(s) is(are)available, all red tag items are tagged, and monitoring list is updated.
    5- 5S Red tag area(s) is (are) available, all red tag items are tagged, and monitoring list is updated and 5S red tag flow chart & PIC is available.

  • 2.2) Is 2S (Set to order) being practiced and maintained.
    Areas to be assessed, if applicable (non-exhaustive):
    - Label / Signage
    - Footprint.
    - Tooling storage/Tools mapping with logbook.
    - Material Inventory storage.
    - Consumables storage.
    - First-in-First-out implementation.
    - Min-Max implementation.
    - Fluid flow arrow marking.
    - Gauges specs range marking.
    - Normally Open/Close tagging for valves.
    Definition:
    1- 5 non-compliances or more per macro zone on Set-to-order non-compliances.
    2- 4 non-compliances or more per macro zone on Set-to-order non-compliances.
    3- 3 non-compliances or more per macro zone on Set-to-order non-compliances.
    4- 2 non-compliances or more per macro zone on Set-to-order non-compliances.
    5- 1 non-compliance or negligible Set-to-Order non-compliances.

  • 2.3) Is 3S being practiced and maintained?
    Sub Criteria 1 :
    Areas to be assessed (non-exhaustive) :
    - Wire and hose dressing.
    - Presence of dust, dirt, grime, oil and other
    contaminants.
    - Restoration of torn and faded labels or any visual
    materials.
    - General restoration on equipment or working areas.

    Definition:
    1- 5 non-compliances or more per macro zone on 3S (Shine) non-compliances.
    2- 4 non-compliances or more per macro zone on 3S (Shine) non-compliances.
    3- 3 non-compliances or more per macro zone on 3S (Shine) non-compliances.
    4- 2 non-compliances or more per macro zone on 3S (Shine) non-compliances.
    5- 1 non-compliance or most of the items are clean and duly restored.

  • Sub Criteria 2:
    - Improvement activities to eliminate root causes or source of contamination

    Definition:
    1- Improvement activities to eliminate root causes or source of contamination has been planned.
    2- Improvement activities to eliminate root causes or source of contamination has been implemented.
    3- Improvement activities to eliminate root causes or source of contamination has been implemented.
    4- Improvement activities to eliminate root causes or source of contamination has been implemented with effective result.
    5- Improvement activities to eliminate root causes or source of contamination has been implemented with effective result.

  • Sub Criteria 3:
    - Cleaning and disinfecting tools.

    Definition:
    0- Cleaning and disinfecting tools not available. Cleaning and disinfecting checklist not available.
    5- Routine cleaning and disinfecting (start and/or end of working hour). Availability of cleaning and disinfecting tools & restoration activities.

3. LUBRICATION & BOLT TIGHTENING

  • 3.1) Has the identification of lubricating points and surfaces & bolt tightening been made?
    - Diagram of lubricating points and surface.
    - Diagram of Bolt Tightening points.

    Definition:
    1- Not done.
    2- Only list of lubricating points and surface made available.
    3- List and diagram of lubricating points and surface made available.
    4- List and diagram of lubricating points, and lube system flowcharts and surface made available.
    5- List and diagram of lubricating points, and lube system flowcharts and surface made available.

  • 3.2) Has the setting of lubrication & bolt tightening control rules been applied?

    - Lubricants listed, and being assigned code and color-coded.
    - Label indicating viscosity, lubrication intervals, and work allocations.
    - Lubricant control rules.
    - Lubricant level visuals.
    - Lubricants fluid flow arrow marking.
    - Bolt tightening marking.
    - Bolt tightening torque specifications (if applicable).

    Definition:
    1- Barely Applied.
    2- 2 of the control rules were not applied.
    3- 1 of the control rules were not applied.
    4- All were applied appropriately.
    5- All were applied appropriately with creative visuals.

  • 3.3) Can everyone clean and lubricate in accordance with standards? If not, are adequate plans and schedules prepared?

    Definition:
    1- Nobody can.
    2- Only Leader is able to perform, with the help of maintenance personnel.
    3- Only Leader is able to perform without the help of maintenance personnel.
    4- Some of the members are able to perform.
    5- More than half of the members are able to perform.

4. KPI

  • Is the KPIs improving?
    Sub-Criteria 1:
    OEE

    Definition:
    1- OEE has declined.
    2- OEE remains about similar.
    3- OEE improved by 1- 5%.
    4- OEE improved by 5-10%.
    5- OEE improved by 5-10%.

  • Sub-Criteria 2:
    Major accident case - Class 1: More than 3 mandays loss.
    Minor accident case - Class 2&3: Less than or equal to 3 mandays loss.

    Definition:
    1- Major accident case > 1. Minor accident cases > 3.
    2- Major accident case = 1. Minor accident cases > 3.
    3- Zero major accident case. Minor accident cases ≤ 3
    4- Zero major accident case. Minor accident cases ≤ 3.
    5- Zero major accident case. Minor accident cases ≤ 3.

COMPLETION

  • Completed By : (Name &Signature)

5S Checksheet

2. HOUSEKEEPING

  • a) Is 1S being practiced and maintained?
    -Unwanted items including leftover foods /FOD
    - Identify,segregate and label of scheduled waste or general waste with PIC
    -Unsuitable / incorrect tools used by the user

    Document:
    - 5S Red tags.

    Definition:
    1- > 5 unwanted items found and not identified.
    2- > 5 unwanted items found. They have been identified but not yet removed.
    3- < 5 unwanted items found. They have been identified but not yet removed.
    4- No unwanted items but no evidence of sustainability.
    5- No unwanted items system being established to ensure sustainability.

  • b) Is 2S being practiced and maintained?

    Areas to be assessed, if applicable ( non-exhaustive):
    '-Label, Footprint,Tagging, Signage, Filing system
    - Tooling storage, material inventory storage, consumables storage, stationery storage
    - Common/ Personnel stationery
    - Staff movement / Machines ownership available / PIC.
    - First-in-First-out / Min-Max implementation
    - Chemical storage or cabinet (e.g. chemical list, PIC and safety data sheet) and Chemical bottle (e.g. label and servicable tag)
    - First aid kit (e.g. quantity, label and PIC)
    - Fire fighting system (e.g. fire extingusher / hose reel and PIC)
    - Racks well maintained; tools and materials properly stacked and spaced; and adequate lighting at work areas.
    - Dangerous machine parts adequately guarded (follow as machine manual).
    - No obstruction on fire escape route and fire fighting system (e.g. fire extinguisher/hose reel/hydrant)
    - Elevators, hoists, conveyors, etc. properly used with appropriate signals and directional warning signs
    - Adequate of PPE equipment provided, maintained, stored and used
    - Emergency safety showers and eye wash stations in good working condition
    - PMA/PMT/PMD (registered equipment) updated, valid and displayed

    Definition:
    1- ≥4 non-compliances per microzone on Set-to-order non-compliances.
    2- 3 non-compliances per microzone on Set-to-order non-compliances
    3- 2 non-compliances per microzone on Set-to-order non-compliances.
    4- 1 non-compliance microzone on Set-to-order non-compliances.
    5- No or negligible Set-to-Order non-compliances

  • c) Is 3S being practiced and maintained?

    Sub-criteria 1
    - Wire and hose dressing.
    - Presence of dust, dirt, grime, oil and other contaminants.
    - Restoration of torn and faded labels or any visual materials.
    - General restoration on equipment or working areas.
    - Rodents and smell-free working area.


    Definition:
    1- ≥3 non-compliances or more per microzone on 3S (Shine) non-compliances.
    2- 2 non-compliances per microzone on 3S (Shine) non-compliances.
    3- 1 non-compliance per microzone on 3S (Shine) non-compliances.
    4- Most of the items are clean and duly restored.
    5- Most of the items are clean and duly restored.

  • Sub-criteria 2
    - improvement activity

    Definition:
    1- Improvement activities to eliminate root causes or source of contamination has been planned.
    2- Improvement activities to eliminate root causes or source of contamination has been implemented.
    3- Improvement activities to eliminate root causes or source of contamination has been implemented.
    4- Improvement activities to eliminate root causes or source of contamination has been implemented with effective result.
    5- Improvement activities to eliminate root causes or source of contamination has been implemented with effective result.

  • Sub-criteria 3
    - cleaning and disinfecting tools

    Definition:
    0- Cleaning and disinfecting tools not available. Cleaning and disinfecting checklist not available.
    5- Routine cleaning and disinfecting (start and/or end of working hour). Availability of cleaning and disinfecting tools & restoration activities.

  • d) Building maintenance. Is 5S (Sustain) being practiced and maintained.

    Sub-criteria 1:
    Condition of wall, ceiling & floor :
    -Floor maintenance
    -Wall maintenance
    - Ceiling maintenance
    Note:
    Issuance of SRF and tagging will be considered as no non compliance.

    Sub-criteria 2:
    Issuance of SRF and tagging will be considered as no non compliance.
    Document:
    Email ,SRF, TDL,Minute of meeting

COMPLETION

  • Completed By : (Name &Signature)

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