5S audit checklist: Ready to use template & how to modify as you need.

Why we need correct 5S audit checklist template?

The aim of the 5s lean manufacturing were to ease the work. But sometimes it goes in wrong way, if the auditor and the auditee are not goes in same perceptions. This why 5S audit checklist are vital.

5s audit can be roadblock for entire 5s program. Because of the missalignment on what actually being audited and what the auditee doing in daily jobs. If this disengagement still continues the 5S performance and impacts may goes in a wrong way and in the end diminish the essentials of the 5s value.

Do you have the same problem? keep reading to find more.

5S Checklist : leandemy ready to use excel template.

5S are proven effective lean program activities that can enhance culture value. To make effective audit checklist or 5s form. We need to define what are the program purpose. And we need to remind ourselves that in the end. We shall tally between what we are checking and what items being maintained by the auditee.

Based on decde experience, we list out main aspect of 5s audit essentials and put it as common ground to start as 5s audit checklist. Which is you can download it in link below.

5s AUDIT Checklist excel Tempelate

To give you simple thought we had 5s Audit checklist template available. We will discuss key aspect of 5s audit template suitable for your needs.

In each section in the 5s checklist. Starting with the main template that you can download for free, which are leandemy.com basic 5s audit checklist for manufacturing. The checklist starting with detail of auditor name & date. And the scoring of each section from the checklist the aspect cover, size of checklist, scoring method, Audit queries & checklist training deployment.

even though we have the ultimate checklist befitting 5s program, here some point that is main aspect of modify 5s Audit checklist.

First: 5s checklist template size

The first aspect I will discuss about the size of the template. In my experience industry there are only two kinds of size used most. And each size has its own benefit for example in operation you want to have some card sized A5 rather than paper A4. Since A5 size scorecard also has disadvantages which is not much item we can listed in the card. It Is suitable if the team are already familiar with 5S and able to grasp each query of the template.

In the other hand, if you want to make the checklist are visible in dashboard, we can prefer A4 landscape format below. it is perfect if you have space for the board and as well as used in digital template. By extracting the template into PDF for example using pdf and make it fillable. Nowadays operator or even foreman are equipped with iPad to digitalize their work.

Template size summary

There is no bounding rule in this particular aspect. in the end each size had their own strength and weakness. you can choose which are more suitable for your team or organizations. Here we made a table of size loss/benefit for your considerations

Second: 5s checklist audit score card & evaluation method

Yes, you read it right even though this might obvious topic for the seasonal lean practitioner. It was important aspect to discuss tough. Form my observation this is where the starting point of the 5s program successful applications. We may define several scoring methods. Each method may be suitable for certain aspects of conditions depend on the occasion. here 3 methods of how 5s audit scored check it below.

The 5s Audit scoring method: Score of consistency 0-4

The first method is to score based on deviations by number 0 is not sustainable at all. While number 1 we can saw pattern of implementation. Not all the group shifts done the activities in similar ways. Or we can say that the 5S sustain at level 1 (short). and goes on until number 4.

This method is recommended by Sitemate.com. Also, it is suitable for sustaining 5s program that have been rolled out for several years. Since it will be easier to calculate and compile the result. If you are trying to use this for new program please keep in mind, when we use this method of scoring. There will be difficult to visualize and describe deviations from the standard if your team are just roll out the 5s program.

If you think you able to deliver the message to the new team of 5s you are good to go. This method may very common everywhere, either in office or manufacturing. during my first job being audited by the HR for the 5s in workplace. I still remember the score result shown 3 where moderate deviation occur.

The 5s Audit scoring method: Score of Effort 0-5

5s scoring method recommended by 5stoday.com are based on effort shown in each particular items. The score card developed by 5stoday.com are good example and practical scorecard audit in office or distributions center. since in the manufacturing usually all the things had already settled. This method may be good for you which are trying to implement 5S outside manufacturing.

The 5s Audit scoring method: Score of deviation finding convert to percentage (0-100%)

As for 5s audit, we think that the most suitable for new 5s implementations are based on number of deviations from 5s standards. This method will show consistency of 5s and also tracking with previous audit. and for scoring we are using percentage to give data granularity.

The score starts with 0 deviations which will give the audit checklist items 100% score. For 1-2 deviations will results 80% score, and so on decrease 20% when there another deviation. Those are basic 5s scoring it is simple and will give clear picture of how the 5s performance against the deviations.

Below is example how the scoring implements on the first “S” of “5S”. If you notice the overall score are calculated based on sum of all result evaluation criteria divided by number items.

5s audit scoring overall suggestions

I think there are no bounding rule in 5s scoring audit. The implementation deployment was key in this particular aspect. depending on your situations, if you are managing area cover office and operation. From the description above that the first method are most suitable for both operation and office area. While second method for office only and third method for operations shopfloor.

Third: 5s Audit queries & essentials aspects to consider

This is interesting topic, which I think quite broad if we discussed both in the office and shopfloor. To narrow down the topic, I will focus on the shopfloor checklist only. as for the office part you can define it easier than the shopfloor part. let’ get into it

5s Audit queries aspect for Short

Before we are getting into the details of short, let’s think back what the main idea of the first step is. It is to ensure that only needed are present in working area. We further categorized working tools in this aspect consist of:

5s Audit queries aspect-Work in progress of work piece,

in manufacturing many processes adopted batch productions. However sometimes it makes the WIP which are slow moving get in the way. Also, it may cause redundancy of wrong work piece are being processed. To avoid these please ensure only work in process as needed in one cycle batch are present.

Tools & equipment,

The definition of this category is all the things are needed to do the main job. Either it is the machineries, or the tools used to set up the changeover. May it consist of wrench, Dies, Pliers all the thing shall identified during the first initiations of 5s program. You can discuss with the program team how to store the tools more appropriate way. In general view of managing the tools consistency are vital part and followed by prompt actions of storing the equipment after used.

Paperwork

For some industry it being less used since current trends are prone to digitalization. Since the cost of digitalization cost around 2 billion dollars for capitalization not all manufacturing adapts full version, they may adopt at some extend had paperwork.

On managing paper worksheet shopfloor are flooded by checklist to ensure all the things run well. I observed sometimes the non-related paper worksheet are there also or the conditions are worn & torn. this is not favorable since other than the cleanliness the paper document data may withered.

Facilities

These aspects may sometimes confuse the 5s program leader. How can we differentiate between the tools and facilities. in my view the tools are the only thing that we used for main SOP, while facilities tools are belong to non-primary activities. For example, Cleaning the line area using the broom are not main working task to create the work piece. Hence, we can deduct that broom are facilities.

Those are main aspect of work tools need to identify in short, if you are working in other area you can add on match your needs. For example, you are working in the lab or pharmacy, you can add on Laboratory glassware and remove the unwanted aspects. Need to remember during your first-time launch 5s not only sorting are the key activities. set up the basic storing condition as standard also vital. This is to ensure the 5s program continuity.

5s Audit queries aspect for Set in order

I think of many people are get the message wrong in this step. For set in order other than aspect of thing need to be checked the approach are more or less do your equipment arranged or stored comfortably?

Ergonomic aspects

Those questions are not limited to how human ergonomics for some extent. If you audited shopfloor area, please think of how comfortable you are. If you are the operator doing the task 8 hours a day. Imagine the things are not comfortable such as storing tools in overhead area or keep the private belongings nearby the machineries since no designated area for those.

The ergonomic aspect cover of how the tools accessibility, walkway space, the illumination of lights, how the air conditioning and relative humidity being maintained. also, the things are quite essential were how your tools stored matching your working sequences.

Work sequence

Other thing you need to consider are the order of tools stored. In first step of 5S short we only account for stored area not the soring conditions. We can further develop in detail how to match the working sequence. By doing so the impact in 5s program will be doubled. Not only your team had neater place to work also reduce the time to cleaning.

Often in kaizen week I did 5s refreshment in set in order aspects. Why? because when the stakeholder request for reduced time changeover. I observe that this tiny aspect is the main cause of the longer time changeover. The tools storing conditions are not considering the walking time. Sometimes even the quantity of the tools available are less than required.

5s audit queries aspect for shine

At this section before you are deploying the query it will be good idea to see how the cleaning have been done. It is best to see how each team member in 5s are split their responsible area. At this section the ownership is vital. and if we deploy cleaning area in not proper balance the team might lose interest and, in the end, not doing the cleaning as per required period.

Also, it was good idea to monitoring the cleaning time over the time. What I observed were once the 5s mature enough the cleaning time shall be minimized. How to do that? we can use the framework of Single minute exchange dies or SMED mindset. It is the concept of parallel work. By doing small cleaning in the daily routine essentially will reduce the cleaning time overall.

5s audit queries aspect for Standardize & Sustain

At this step I think your 5s program are mature enough. Because based on several experience roll out 5s program, it is best to implement 5s audit in step 1-3 first. And then continue 4 and 5 after one semester. Either way it more less difficult to make the audit checklist. Since you may come with several changes on the checklist.

The mindset you need to put at this section were how if new member came and identified the 5s program easily. I could think of using the visual control as one part of lean manufacturing tools came in play. we also may use the label and some extent we can use poka-yoke as for error proof of the storing conditions.

We had our 5s audit checklist template with the best-case study of standardizations manufacturing best practice. Also, the color-coding standard that may use generally by manufacturing industry.

Fourth: The checklist training deployment

The last aspect you need to consider were the training deployment of the audit checklist. It may sound simple, but it has intrinsic value that cannot be neglected are the level understanding of audit checklist between auditor and auditee. Of course, as the auditor goes it may have more comprehensive understanding in 5s checklist rather than the auditee.

However, nowadays the industry application where they usually rotating the auditor from non-shopfloor department such as HR or finance. The audit finding and overall result sometimes not aligned with the main aim of 5s. It is better that there is basic training delivered before the audit initiated.

As the deployment method I would prefer the old school face to face with additional of how the last audit goes. It is to give the new auditor sense of how the last performance of 5S. The best if you can give the last audit findings and area of improvement.

The Essence of 5S checklist in Workplace Management

In the dynamic landscape of workplace management, efficiency is the cornerstone of success. One powerful methodology that has proven to be a game-changer is the 5S system. In this blog post, we’ll delve into how implementing 5S principles can significantly improve workplace management, with a spotlight on the indispensable tool known as the 5S audit checklist.

PDCA concept and 5s program

For instance, in ISO 9001 Quality Management Systems, the PDCA cycle involves tools like PFMEA, HACCP, X matrix, and balanced scorecards in the planning phase, 5S checklists and TPM checklists in the doing phase, layered process audits and internal audits in the checking phase, and OKR program deployment and kaizen in the acting phase.

Similarly, in ISO 45001 Safety Management Systems, tools like HIRADC, HAZOP, behavior observations, 5S checklists, and LOTO checklists are strategically employed across the PDCA cycle.

The Excellence KPI Translation to 5S metric

Translating excellence Key Performance Indicators (KPIs) to 5S metrics, these daily forms become core basic tools. Not only are they implemented widely, but they also serve as training mechanisms for new members. Graphs depicting the percentages of 5S lean and standardized work underscore their central role in achieving and maintaining operational excellence. As organizations navigate the intricacies of modern industry, the synergy between 5S daily forms and standardized work emerges as a cornerstone for sustained success

Overall Summary

In conclusion, the 5S methodology stands as a potent catalyst for improving workplace management.

By embracing the principles of Sort, Set in Order, Shine, Standardize, and Sustain, organizations can cultivate an environment of efficiency, productivity, and continuous improvement.The 5S audit checklist emerges as a vital companion in this journey, providing a structured approach to assess and enhance the application of 5S principles.

As businesses strive to optimize their operations and elevate workplace management, the combination of 5S principles and the 5S audit checklist proves to be a winning formula for sustained success.

Those 4 are the key aspect to consider deploying your 5s audit checklist or template. The main idea is to have the correct size, after that you need to consider the scoring method. at this point you will have the general idea of the physical ideas how the checklist formed.

As for the audit query there are several aspects you need to consider. The first are the working tools type, whether it was tools, paperwork, facilities personnel belonging and WIP or there is other need to consider. As well tally between program progress with last 4 And 5 “S”. Which is also important to the overall program sustainability.

If you think still had the vague idea how the query is, you can download the ready to use 5s checklist.

Thanks for reading here some blog post related to the 5s program:

5s Audit Principle, benefit and key tools you need to know

How to plan 5s Audit [Bonus! 5s audit checklist Free template]

do you agree with this article or there might problem that arise during your 5S program? give us feedback or comment below.