Inspection Page

  • Are you AM auditor or 5S auditor

AM Checksheet

1. SUSTAINING AM STEP 1,2 AND 3

  • a) Is there evidence that AM activities plan being made in advance and participated by all members?
    - Master / Group schedule
    (Building maintenance activities available in Master Plan eg. floor maintenance, wall maintenance and ceiling maintenance)
    - Team organization inclusive of maintenance members
    - Layout / Ownership
    Is AM Step 1, 2 & 3 training for microzone leaders, PIC machine and team members conducted?
    - Training record, training module

    Definition:
    1- None
    2- Available but information were not completed.
    Only the leader was trained with AM Step 1-3 general awareness
    3- Available but information were completed partially.
    All were trained with AM Step 1-3 general awareness.
    4- Available but some information not completed and updated.
    All were trained with AM Step 1-3 standard document and microzone leader can
    be a trainer.
    5- Available, information are complete and all were updated.
    All were trained with AM Step 1-3 standard document, microzone leader and
    PIC machine can be a trainer.

  • b) Is there evidence that AM activities being carried out at regular basis?
    - Meeting Minutes, memos or document used to communicate with regards to AM activities.
    - Attendance list
    Is cleanliness in previous step well maintained?
    - Cleaning standards, Cleaning reduction time & Difficult cleaning area
    - Disinfectant schedule and activity.

    Definition:
    1- None. Poor condition.
    2- Not consistent. Cleanliness at below average condition.
    3- Meetings were done consistently but poor attendance (<60%).
    Cleanliness at average condition.e allocation is sufficient and activity was
    done consistently.
    4- Meetings were done consistently but poor attendance (61-99%).
    Cleanliness at above average condition.There are cleaning and disinfecting
    schedule.
    5- Meetings were done consistently with 100% attendance.
    Cleanliness at excellent condition. Cleaning and disinfecting activities are as per
    schedule.

  • c) Are the basic equipment conditions attained by Step 3 well maintained?
    - Lubricants & bolt tightening control rules, visual management
    - Lubricants & bolt tightening standards, flow charts, diagrams
    - Lubricants & bolt tightening inspection checksheet
    - Difficult lubrication & tightening areas

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

  • d) Is there evidence fuguai detection and restoration being carried out on regular basis to support AM Step 1 - 3 activities?
    - Fuguai tags, summary & mapping

    Definition:
    1- None
    2- 1 to 5 fuguais recorded & tagged however auditor still can find other fuguais
    not tags. Needs improvement. ≤50% Close out rate
    3- 6 to 10 fuguais recorded & tagged and auditor still find other fuguais not tags.
    Fairly good ≥50% Close out rate.
    4- >10 fuguais recorded & tagged and auditor still find other fuguais not tags.
    Fuguai mapping completed. Good 100% Close out rate
    5- Fuguais were tagged and auditor cannot find any fuguai not tagged. Fuguai
    mapping completed. Good 100% Close out rate.

  • e) Are residual issues left from previous step resolved?
    - Pareto analysis, Why-why analysis
    - Kaizen report / Before-After
    - Audit activities
    - OEE analysis / Performance ratio / MTBF

    Definition:
    1- None
    2- All summary are not complete. Many data/info missing.
    3- Some summary are not complete. 20% data/info missing.
    4- Summary are completed and being used to support request from
    other section actions.
    5- Summary are completed and being used to support request from
    other section actions. 80% problems were solved.

2. INSPECTION EDUCATION AND CHECKSHEET

  • a) Inspection manual development
    - Inspection manual had been developed and understood by members
    - Machine diagram availability
    - All the parts type, name, structure and function of equipment clearly explained
    - Phenomena, causes, criteria, evaluation and remedies of equipment defects
    understood. All members can inspect equipment..

    Definition:
    1- None
    2- Available but not updated. Many information not complete. Not all members can
    inspect.
    3- Available but partially updated. Some information were not complete. Some
    members can inspect.
    4- Available, some information not complete and updated. All the members can
    inspect.
    5- Available, information are complete and all were updated. All the members can
    inspect.

  • b) Overall inspection checksheet
    - Inspecting standards had been developed and understood by members
    - All inspection point are identified.
    - Inspecting time targets, checking standards and specifications, work allocation
    and areas are clearly identified.
    - Overall inspection checksheet being used by members

    Definition:
    1- None.
    2- Available but not updated. Many information not complete. Not all members
    use inspection checksheet.
    3- Available but partially updated. Some information were not complete. Some
    members use inspection checksheet.
    4- Available, some information not complete and updated. All the members use
    inspection checksheet.
    5- Available, information are complete and all were updated. All the members
    use inspection checksheet.

  • c)Is Plant maintenance handover had been carried out?

    - Training conducted by competent person / Maintenance engineer
    - Training from maintenance to members had been conducted
    - Training material, notes or manual
    -Training attendance

    Definition:
    1- None
    2- Available but some information were not complete. Only the leader were
    trained.
    3- Available but information were partially completed. All were trained.
    4- Available, some information not complete and updated. All were trained.
    5- Available, information are complete and all were updated. All were trained and
    microzone leader can be trainer.

  • d) Is members inspection skill being evaluate?
    Document:
    - Training evaluation result (% passed)
    - Skill chart (% competent)

    Definition:
    1- None
    2- Not all members were evaluated and competent for AM responsibility
    3- All members were evaluated and competent for AM responsibility
    4- All were evaluated and competent. Only micorzone leader are competent in
    problem solving.
    5- All were evaluated and competent. Microzone leader, PIC machine are c
    competent in problem solving.

3. SAFETY INSPECTION

  • a) Are safety equipment functions properly / personal protective equipment available?
    - Safety inspection sheet / Hazard Diagram
    - Personal protective equipment
    - KYT sheet
    - Avaibity of First aid kit, List of First aid items

    Definition:
    1- None
    2- Available but not updated. Many information not complete. Not all members can inspect.
    3- Available but partially updated. Some information were not complete. Some members can inspect.
    4- Available, some information not complete and updated. All the members can inspect.
    5- Available, information are complete and all were updated. All the members can inspect.

  • b) Diagnose location
    - Minor defect on safety are being restored and well maintained
    - Availability of safety signage and eye see label
    - Existence of flammable and dangerous goods at machine area (chemical, Zink, thinner etc)
    - Existence of excessive noise, air leak, oil leak

    Definition:
    1- Poor condition.
    2- Below Average condition.
    3- Average condition.
    4- Above Average condition.
    5- Excellent condition.

4. FASTENER INSPECTION

  • a) Are condition of bolts and nuts well adequate?

    '- All bolt had been marked
    - No corroded, loose or bent nuts and bolts
    - Minimum two threads exposed and no damaged threads
    - Correct length of bolts
    - Looseness prevention methods such as washers properly used
    - Double nuts or match marks used for critical bolts

    Definition:
    1- Poor condition
    2- Below Average condition.
    3- Average condition.
    4- Above Average condition.
    5- Excellent condition.

  • b) Are all discovered defective parts corrected?
    - Tool available for corrective actions
    - Fuguai tag and summary
    - Breakdown summary (Bar graph, pie chart, pareto chart)
    - Problem solving report / Why-why Analysis
    - Problem escalation to maintenance (Repair order)
    - Maintenance to prepare MTBF

    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 were updated.
    5- Available, information are complete and all were updated with effective result.

5. POWER TRANSMISSION INSPECTION

  • a) Are condition of motor, belts, pulleys, chains, sprockets in good condition?

    - No deteriorated or oil contaminated belts. Are belt tensions proper. No worn or misaligned pulleys
    - No wear or slack in chain or sprockets. No oily contamination around chains
    - No damage, misalignment, loose fixtures or play in shaft. No overheating, vibration or noise at bearings
    - No noise, vibration or overheating at gears, breaks
    - Critical areas visible through safety cover. Covers are adequately modified

    Definition:
    1- Poor condition
    2- Below Average condition.
    3- Average condition.
    4- Above Average condition.
    5- Excellent condition.

  • b) Are all discovered defective parts corrected?
    - Tool available for corrective actions
    - Fuguai tag and summary
    - Breakdown summary (Bar graph, pie chart, pareto chart)
    - Problem solving report / Why-why Analysis
    - Problem escalation to maintenance (Repair order)
    - Maintenance to prepare MTBF

    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 were updated.
    5- Available, information are complete and all were updated with effective result.

6. HYDRAULIC AND PNEUMATIC INSPECTION

  • a) Are hydraulic and pneumatic parts functions properly?

    - No contamination, damage, leakage or vibration in hydraulic and pneumatic equipment, pipes, hoses, valves, fittings or any other parts
    - No abnormal noise, vibration or overheating in rotary machinery, motors, solenoid and selector valves or any other hydraulic and pneumatic parts
    - Are air filters, regulators and lubricators properly installed.
    - Easy to inspect for oil quantity, oil levels satisfactory.
    - No foreign particle in filters and condensed water drained
    - Are pressure gauges, thermometers, level gauges properly installed, easy to inspect and actuating normally

    Definition:
    1- Poor condition
    2- Below Average condition.
    3- Average condition.
    4- Above Average condition.
    5- Excellent condition.

  • b) Are all discovered defective parts corrected?
    - Tool available for corrective actions
    - Fuguai tag and summary
    - Breakdown summary (Bar graph, pie chart, pareto chart)
    - Problem solving report / Why-why Analysis
    - Problem escalation to maintenance (Repair order)
    - Maintenance to prepare MTBF

    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 were updated.
    5- Available, information are complete and all were updated with effective result.

7. FUTURE PLAN

  • a) Are outstanding problems being clearly summarized for action in next step?

    Definition:
    1- No.
    2- All summary are not complete. Many data/info missing.
    3- Some summary are not complete. 20% data/info missing.
    4- Summary are completed and being used to support request from other
    section actions.
    5- Summary are completed and being used to support request from other
    section actions. 80% problems were solved.

COMPLETION

  • Completed By : (Name &Signature)

5S Checksheet

1. GROUP ACTIVITY

  • a) Is there AM Master Plan and group half yearly plan for AM Step 2 activities?
    Document:
    - TQM Master Plan
    - AM group activities schedule.
    - Attendance List
    - Building maintenance activities available in Master Plan e.g. floor maintenance, wall maintenance and ceiling maintenance.

    Definition:
    1- None
    2- Available but members were not aware hence not done.
    3- Available and members are aware of the plans but activities were partially done.
    4- Available and all activities were being done.
    5- Available and all activities were done on schedule and evidence are documented.

2. HOUSEKEEPING

  • a) Is 1S being practiced and maintained?
    -Unwanted items /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- All items were not were not properly arranged and labeled.
    2- Some items were not properly arranged and labeled.
    3- All items were labeled but require improvement in arrangement.
    4- All items were properly arranged and labeled.
    5- All items were arranged and labeled. They are also clean,tidy and user friendly.

  • 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.


    Definition:
    1- 1) ≥3 non-compliances or more per microzone on 3S (Shine) non-compliances. 2) Improvement activities to eliminate root causes or source of contamination has been planned.
    2- 1) 2 non-compliances per microzone on 3S (Shine) non-compliances. 2) Improvement activities to eliminate root causes or source of contamination has been implemented.
    3- 1) 1 non-compliance per microzone on 3S (Shine) non-compliances.
    2) Improvement activities to eliminate root causes or source of contamination has been implemented.
    4- 1) Most of the items are clean and duly restored. 2) Improvement activities to eliminate root causes or source of contamination has been implemented with effective result.
    5- 1) Most of the items are clean and duly restored. 2) Improvement activities to eliminate root causes or source of contamination has been implemented with effective result. 3) Routine cleaning and disinfecting activity (start and/or end of working hour). Availability of cleaning 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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