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

5S audit  are essentials program in lean manufacturing Tools. Tied with gemba walk It’s widely known as basic tools to enhance the lean culture and productivity.  Many mistakes are bound to happens since the 5s buzz words are everywhere. Yet small amount of relevant guide to deliver successful 5s lean manufacturing are rarely present.

How to do 5S Audit  steps by step.

We breakdown into 6 stages on how to plan 5s audit. which are following:

Step 1. Identification of program charter

Step 2. Definine 5s area focus

Step 3. Developing 5s audit checklist

Step 4. Deploy 5s pilot program (area group)

Step 5. Cross audit of 5s area

Step 6. Reward & recognitions.

5s is Key important program In Shopfloor or operations. Because lean transformations Is not only about Cost. Halso need to cover human Interaction or working culture. Since it will be vital for Sustainability.

Based on Research only 5% of Lean program are able to sustain after 4 years. This may happen due to , Lack Sense of Sustainability in to design of lean System during transformation Project.

leandemy.com had decade of experience of lean program & transformation. by using our ready to Use template & knowledge to Streamline Your lean Project

Step 1. Identification of standard and Program Charter

5s is Key important program In Shopfloor or operations. Because lean transformations Is not only about Cost. Halso need to cover human Interaction or working culture. Since it will be vital for Sustainability.

Based on Research only 5% of Lean program are able to sustain after 4 years. This may happen due to , Lack Sense of Sustainability in to design of lean System during transformation Project.

There are Several aspect Of Standard we need to take a look during 5S audit deployment Which Is:

1. Floor Color marking or Color Coding

2. Procedure of Red tag’s & Blue tag’s

3. Work in progress management

4. Certificate of labor agreement

leandemy.com had decade of experience of lean program & transformation. by using our ready to Use template & knowledge to Streamline Your lean Project.

Some of the companies which had implemented lean manufacturing several years will have good guidelines such as color coding for shopfloor, office desk utensil placement and such. And common question for company which started 6S this will be daunting jobs if you had no standard for shopfloor line marking for main aisle pedestrians even for raw material and semi-finished material, we ended different color coding. At leandemy you can download such resource and straightly focused on your implementation.

Step 2. Definine 5s area

Some of business leader eager to conduct the whole ‘’S’ of the 5S in the first run. Meanwhile it gives good report but in the long run it will give them sense of heavy burden. Since many things to done to get good result. Step by step program and give sense of accomplishment to the team. This method proven to give more sustainability rather than implementing the whole aspect of 5S

Step 3. Developing 5s audit checklist

This is important part that keep the program alive the chance of 6s activities and campaign failure are higher if there were no cross audit because there no new eyes for the location subject ot be audited. And it will be really good to had mix and match like HR Département doing cross audit for Maintenance or production and vice versa.

here our ready to use 5S audit Checklist

Step 4. Deploy 5s pilot program (area group)

If you are failed to plan you are planning to fail, those quotes are also becoming the first advise of to deploy 6S program. Because we need to really understand how much the area coverage highly related to manpower resources and team competition later. Also, the leader commitment of the 6S area program support since we need to do cross audit

Step 5. Reviewing 5s program periodically.

Indeed, Without Proper 6S training program the whole masterplan will be useless, the training we suggest will discuss about all elements of 6S activities including 6S principle, Standard, checklist also the auditing score. With complete training program it will ensure the program success rate since everybody on the same page and increasing enthusiasm with cross functional audit.

This is important part that keep the program alive the chance of 6s activities and campaign failure are higher if there were no cross audit because there no new eyes for the location subject ot be audited. And it will be really good to had mix and match like HR Département doing cross audit for Maintenance or production and vice versa.

Step 6. Reward & recognitions.

Many businesses leader assume for celebration require great amount of financial resource

Meanwhile it doesn’t in actual live, you may be only needed to bring the highest team. Certificate or even trophy which can be seen in their workstation. And communicate them during event such as townhall in the factory. It will give them feeling of self-accomplishment and acknowledgement. Many 6S program dies out due to inconsistency. It means by doing reward for the most performing line will give sustainability for the program.

5S Audit Tips 

5S program are put first when the company or an organization try to develop lean manufacturing initiatives. As many of top manufacturing implementing this program also many companies had pitfall here some tips to deploy good 5S program here to be an effective 6 S program

Since it first release in 1997 Masaaki Imai book Gemba kaizen are eye opener for the world of manufacturing industry practice. In this book he also quotes that many manager supervisors and engineers intend to seek more high-cost technology rather than common-sense low-cost approach. He also develops House of Gemba which some of the main baseline pillars were 5s.

He also introduces several key practices in shopfloor and the rose of lean tools which also 5s began.  5s buzz words are Everywhere, yet small amount of relevant guide regarding 5s tips are present.

Conclusion

In conclusion, 5S audits are an essential component of lean manufacturing tools and play a significant role in enhancing lean culture and productivity. While the concept of 5S is widely recognized, there is a lack of comprehensive guidance for successfully implementing 5S in lean manufacturing.

The blog has outlined a step-by-step process for planning a 5S audit, which includes stages like identifying the program charter, defining the areas of focus, developing audit checklists, deploying pilot programs, conducting cross-audits, and implementing reward and recognition systems.

5S is vital in shopfloor and operations because it not only reduces costs but also focuses on human interaction and working culture, which is crucial for long-term sustainability. Research has shown that only a small percentage of lean programs are able to sustain their improvements after several years, often due to a lack of sustainability in the initial design of the lean system during transformation projects.

To ensure the success of a 5S audit, it’s important to have clear standards and program charters, including aspects such as floor color marking, red tags, blue tags, work-in-progress management, and labor agreements. These standards help maintain consistency in implementation.

Defining 5S areas incrementally rather than attempting to cover all “S” elements at once can lead to more sustainable improvements. Developing a 5S audit checklist is essential to keep the program on track, and cross-auditing by different departments and teams can provide fresh perspectives and insights.

Deploying 5S pilot programs requires meticulous planning, considering factors like the area’s coverage, resource allocation, and leader commitment. Regular reviews of the 5S program are crucial to keep it alive and ensure it doesn’t become stagnant.

Finally, reward and recognition play a significant role in maintaining enthusiasm and consistency in 5S programs. It doesn’t necessarily require large financial resources; a simple certificate or trophy can make a significant difference in motivating teams and acknowledging their efforts.

In summary, 5S programs are fundamental to lean manufacturing, and successful implementation involves careful planning, regular reviews, and a commitment to sustaining improvements over the long term.