CTRM - AM5S Step 3 Audit FY2024

Title Page

Microzone Area
Machine Name
Microzone Leader
Date & Time
Auditor

Inspection Page

Are you AM auditor or 5S auditor
- AM auditor
- 5S auditor

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

1) 1S Sorting activity

Is 1S (Sort) being practiced and maintained Sub criteria 1: Non-compliances include : 1. Unneeded items i.e leftover foods 2. Foreign Object Debris (FOD) others than dust 3. Identify, segregate and label of scheduled waste or general waste with PIC 4. Unsuitable / incorrect tools used by the user 5. Masking tape at regulators
- 0) No or very little sorting activities
- 1) 3 non-compliances per macro zone whereby unneeded or misplaced items are found.
- 2) 2 non-compliances per macro zone whereby unneeded or misplaced items are found.
- 3) 1 non-compliance per macro zone whereby unneeded or misplaced item is found.
- 4) No unneeded or misplaced items found except those at red tag area(s).
- 5) No unneeded or misplaced items found except those at red tag area(s).
Sub criteria 2: Options available: 1. Centralized or multiple tag by zones 2. Red tag flow chart is to be approved by 5S Chairman (COO)
- 0) No red tag area available
- 2) Red tag area(s) is(are) available.
- 3) Red tag area(s) is(are)available and all red tag items are tagged.
- 4) Red tag area(s) is(are)available, all red tag items are tagged, and monitoring list is updated.
- 5) 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.

3) 2S Set to order activity

Is 2S (Set to order) being practiced and maintained. Areas to be assessed, if applicable ( non-exhaustive): Area Demarcation - Footprint / Lining / Marking Visual Controls - Signage - Labels and PIC -Point of use (POU) - Personal stationery - Chemical bottle (label, service tag i.e) - Racks well maintained; tools and materials properly stacked and spaced; - Dangerous machine parts adequately guarded (follow as machine manual). Storage Location - Consumable storage - Material Inventory storage - Stationery storage - Toolings storage - Chemical storage/cabinet System establishment - FIFO - Min / max - Filing system Safety - Chemical storage or cabinet (e.g. chemical list, PIC and safety data sheet) - 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) - 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
- 0) A lot of non compliances
- 1) ≥4 non-compliances per microzone on Set-to-order
- 2) 3 non compliances
- 3) 2 non compliances
- 4) 1 non compliance
- 5) No or negligible non compliance

4) 3S Shine activity

Is 3S (Shine) being practiced and maintained Areas to be assessed (non-exhaustive): 1. Wire and hose dressing 2. Presence of dust, dirt, grime, oil and other contamination 3. Restoration of torn and faded labels or any visual materials 4. General restoration on equipment or working areas 5. Rodents and smell free working area. 6. Area brightness within lux standard (refer to lux reading record) 7. POU system availability and workability.
- 0) Not being practiced and maintained at all
- 1) ≥ 4 non compliances
- 2) 3 non compliances
- 3) 2 non compliances
- 4) 1 non compliance
- 5) Most of the item are clean and duly restored
Improvement activities to eliminate root causes or source of contamination
- 1) has been planned
- 3) has been implemented
- 5) has been implemented with effective result
Routine cleaning activity with appropriate tools.
- 0) No routine cleaning and cleaning tools available.
- 5) Routine cleaning activity (start and/or end of working hour). Availability of cleaning tools & restoration activities.
Routine lux recording recorded
- 0) No routine of lux recording recorded.
- 5) Routine lux recording available per schedule.

5) 4S (Standardization) and 5S (Sustain)

Is 4S (Standardization) and 5S (Sustain) being practiced and maintained. Sub-criteria 1 (Standardization): Activity implement per standard established? (score given shall be the same as score given for criteria 2S) Note: No unneeded items (1S). Maintenance activities are available in 5S Master Schedule . Document needed: Email ,SRF, TDL,Minute of meeting
- 0) No evidence of sustaining activity
- 1) ≥4 non-compliances per microzone on Standardization non-compliances.
- 2) 3 non-compliances per microzone on Standardization non-compliances.
- 3) 2 non-compliances per microzone on Standardization non-compliances.
- 4) 1 non-compliance per microzone on Standardization non-compliances.
- 5) No non-compliance
Sub-criteria 2 (Sustain) : Is there any Continuous Improvement activity conducted and been revisit from previous audit/finding? 1. Audit report 2. Genba finding 3. Success Stories (Before/After)
- 2) <50% finding close (within scope) and support document raised (if any) with evidence (before/after).
- 3) >50% finding close (within scope) and support document raised (if any) with evidence (before/after).
- 4) 100% finding close (within scope) and support document raised (if any) with evidence (before/after).
- 5) 100% finding close and action towards document raised (if any) are close with evidence (before/after) and standard established.
Sub-criteria 3 (Building maintenance - Sustain) Compliance of condition of floor, wall and ceiling herein refers to the following matters: 1. Floor maintenance - shine, free from unneeded item, dented, flake, chirp off and others contaminants. 2. Wall maintenance - shine, free from damage, unneeded item, uneven paint, flake, chirp off, watermark (mouldy), handprint and malfunction trunking. 3. Ceiling maintenance- shine, free from dented unneeded item, flake, chirp off, watermark, handprint, leaking, missing ceiling panels
- 0) Not being practiced and maintained at all
- 1) ≥4 non-compliances or more per microzone on wall, ceiling and floor.
- 2) 3 non-compliances per microzone on on wall, ceiling and floor.
- 3) 2 non-compliance per microzone on wall, ceiling and floor.
- 4) 1 non-compliance per microzone on wall, ceiling and floor.
- 5) Most of the items are clean and duly restored for wall, ceiling and floor