Manufacturing 5S Audit - MAINTENANCE- V2.0

• Plant Name & Quarter Audit (ex. Richmond Beverage Q1 5S Audit)

• Quarterly 5S Audit

• Plant Name

• Conducted on

  Date

• Auditor

• Location
  Address

• Present During Audit:

• Scoring Instructions: Do not combine like exceptions, count each exception individually. Example: 4 trash receptacles not in designated location. This is not counted as 1 exception because it is trash receptacles. It is counted as 4 exceptions because of the number of occurrences a trash receptacle was not in its designated location.

1-SORT (Distinguish between what is needed and not needed)

• 1) Is there a designated RED TAG location? Have items been identified for disposal?

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 2) Needed equipment, tools, supplies & parts are present and within the work area. Unnecessary items are removed to proper storage.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENTS:

• Add media

  Media

• 3) Is all trash, rubbish, etc. disposed of? Are receptacles in designated locations?

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 4) No unneeded, out of date, or out of place material on work stations, walls, bulletin boards, etc.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

2-SET (Have a place for everything and everything in its place)

• 5) All permanent and staging locations for moveable items are clearly defined and items are in their proper location. Example: Cart storage, rolling bins, ladders, etc.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 6) Shelves and storage areas are organized, clear boundaries are divided, and labeled. There are no uncertainties about where items are stored. Example: ingredients, packaging, chemicals, etc.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 7) All items are put away immediately after use to its specified location. Frequently used items are stored at the point of use.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 8) GMP aisle ways, workstations, equipment, and locations are clearly indicated.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

3-SHINE (Clean and look for ways to keep things clean and organized)

• 9) Floors, walls, stairs, and visual aids are free of debris (no oil, dirt, chips, etc.) and organized? There is evidence of cleaning being performed in constant manner.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 10) Equipment in the area is free of debris (no oil, dirt, chips, etc.) and organized? There is evidence of cleaning being performed in constant manner.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 11) Stairs, exits, and aisle ways are clearly marked to facilitate work flow and escape routes.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 12) Lighting in the work area is bright and adequate (no bulbs out, no loose light fixtures)

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

4-STANDARDIZE (Maintain and monitor the first three categories)

• 13) Where appropriate, are all documents present updated, appropriately located, and well organized.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 14) Work area is labeled in a uniform manner (pictures, labels, color codes, etc.)

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 15) Visual organization methods are being used where appropriate (shadow boards, floor marking, etc.) and tools are placed in a manner that minimizes unnecessary movements such as walking, bending, or reaching

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 16) Checklist for cleaning is current and available. (Review PMC or posted checklist)

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

5-SUSTAIN (Stick to the 5S rules)

• 17) Has yearly 5S training been conducted for all employees. (Review source of training and employee roster)

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 18) Have monthly 5S audits been performed? (Review last 5S audit performed)

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 19) Were all items on previous audit corrected (Review AIP List)

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media

• 20) The 5S's have become a way of life - there is noticeable continuous improvement.

  Select 0 - 1 Exceptions. Currently meets 5S expectations 2 - 3 Exceptions. Significant 5S progress has been made 4 - 5 Exceptions. There is evidence of activity, although improvements can be made 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred 11 + Exceptions. No evidence of activity being done N/A - Must provide comment

  • 0 - 1 Exceptions. Currently meets 5S expectations
  • 2 - 3 Exceptions. Significant 5S progress has been made
  • 4 - 5 Exceptions. There is evidence of activity, although improvements can be made
  • 6 - 7 Exceptions. Activity taking place, yet there is no consistency or sustained effort visible
  • 8 - 10 Exceptions. There is minimal evidence that 5S activity has occurred
  • 11 + Exceptions. No evidence of activity being done
  • N/A - Must provide comment

• COMMENT:

• Add media

  Media