Auditor Auditee Audit Zone: Audit Date: 5S Audit Check List - Scoring Guidelines [PDF]

Zitiervorschau

MARATHAN MOTORS INDIA PVT LTD

Doc.No:MM/HR/05 Rev.No-00 EFF. Date- 29/01/2020

5S Audit Check List Auditor

Auditee

Audit Zone :

Audit Date

5S Audit Check List - Scoring Guidelines

4S - SeiketsuStandardise

3S - SHINE

2S - Seiton -Set in order

1S - Seiri -Sorting

S.No

Evaluation Status / Criteria

Max

1

Unnecessary items/Materials/ Documents

Rejected Materials, Rework materials, waste materials, damaged items, old records , obsolete documents etc, are regularly identified and removed from place of work and timely disposed off. Red tag system in place.

4

2

Machines, Equipments, spare parts etc.

Unusable machine parts, motors, Equipment, trolleys, are identified periodically as a system, removed from place of work and disposed off regularly.

4

3

Tools, Accessories, Fixtures Broken or unusable Tools, accessories, fixtures are timely identified, repaired if possible for etc. reuse or disposed off on regular basis.

4

4

Used Items

No tea cups & any useless articles on tables, work place & machine.

4

5

Excess parts/Materials (Usable)

Have all the unnecessary items (tools, machines, boxes, etc.) been removed from the work place.

4

1

Layout/Yellow/Green line/Red line

Dividing lines are clearly drawn with Yellow/ Green lines on the floor. Red lines are drawn for storage of rejects/Scrap/Waste materials

4

2

Shelves, Lockers, drawers

Required items are clearly identified and are stored in the departments, Tool crib and Stationary items etc are stored with shadow board concept. Items near machine are identified & stored in pallets/ in bins with appropriate labels.

4

3

Storage Methods

Components are stored in Bins, pallets and trolleys in shop floor with appropriate labels. The items are stored based on the frequency of the usage & size. Nothing on floor concept is evident

4

4

Location Charts

Items are earmarked with Tags. Materials under inspection /Rejections are stored in such a way that they are not allowed to get mixed up and clearly identified with stickers. Item wise location charts are displayed prominently.

4

5

Orderliness

1

Floors

Floors are being clean regularly and kept shine . Water cleaning is done in Assembly floors, toilets, office rooms with detergent regularly.The zone have well identified with tag. Red tag area is displayed properly.

2

Machines/ Equipments/ Computer Peripherals

Machine cleaning & inspection by operator. Handling equipments are cleaned by the respective person. Computer peripherals are cleaned by users regularly.

3

Shelves, Lockers and all Items in Storage

Cleaning of Almirah, shelves, lockers and other storage places in place.

4

Spills, Leakages

Oil, coolants, grease, cleaning agents, paints are not allowed to spill. In case happens immediately attended. No leakage from water taps, air hoses, oil drums etc.

5

Walls, Roofs, windows etc.

No cobweb, no dust is allowed on the walls / roofs/ windows & being cleaned regularly.

1

Standards/ Operating Procedures / Displays

The standards/operating procedures related to operations and house keeping are established with clarity and are displayed in place of use.. Displays are in standard form

4

2

Hazardous Materials/Shelf life items

Hazardous chemicals in the plant & shelf life items are stored separately under stipulated conditions .Safety sinages displayed instruction are in commuincable form.

4

Disinfections

Clean and sparkling toilets, no bird droppings , no pest found in shops/workplace

Over Flows, Leakages

No over flowing of sewage, water logging /stagnation in canals, no leakage of roofs etc. in the work areas.

4

Work environment

Adequate ventilation, lighting being maintained. Temperature and humidity in work areas are comfortable.

4

1

Awareness & Training

Every body in department is trained in 5S awareness,SOP's and safety methods and retrained whenever required.

4

2

Compliance to Standards & Every one adheres to SOP's /appropriate PPE's and ensures others also follows wherever safety instructions required

All items are arranged in a orderly manner and tagged with part numbers with visual control

3 4 5

5S - Shitsuke-Sustain (Discipline)

Check Item

4

4 4 4

4

4

Response to last audit observations through appropriate CAPA, Carryout self audits and corrections ; Egarness to learn and adopt

4

Continual Improvements

No stagnancy in 5S scores; Improvement projects identified to remove unsafe conditions,fatigue reduction, cycle time reduction thro muda elimnation

4

Ownership & pride

Regular reviews by HOD; Demonstration of "This is my workplace . I will maintain it spic and span" Efforts seen to take these systems beyond boundaries

4

5

Prepared by RISHI GAUTAM

4

Team's Responsiveness 3 4

4

Approved by SUSHIL GUPTA

Total

100

Actual

MARATHAN MOTORS INDIA PVT LTD 5S Audit Check List - Scoring Guidelines Following are guide lines for trained internal auditors to allocate score for the audited zones. Internal auditors to compare actual status with the observed status as described below for each of the evaluation of 5S elements. Auditors to take close comparison and then do the scoring. In case of the actual status falls in between two levels say for example Level 0 and Level 1 then auditors can give score points like 0.2, 0.4,0.6,0.8 what the auditors feel more appropriate. It is only auditors discretion

5S - Shitsuke-Sustain (Discipline)

4S - Seiketsu- Standardise

3S - Seiso- Spic & Span

2S - Seiton -Set in order

1S - Seiri -Sorting

Observed Status

Score

Level

Clutterd. No regular sorting out & disposal of excess materials, unwanted items& expired documents

0

L0

Some unwanted, excess materials sorted out once a while and disposed.

1

L1

System exists for disposal of process scrap and waste materials, but needs improvement in all other areas.

2

L2

A well established system is in place of clearing regularly unwanted items, excess items and documents, but delay indispose of excess items

3

L3

Very well established system is in place and standards are being followed by all regularly. Preventive actions are in place to avoidaccumulation of excess materials, unwanted items & expressed documents.

4

L4

No orderly arrangement of items .Too much time taken for locating & issuing items

0

L0

Some signs /displays / organized way of arrangement of items at few places /locations

1

L1

Systematic arrangement in many areas. Yellow/ Red/ Green lines are drawn. Visual control labels are seen in few places to control inventory and prevent stock outs

2

L2

A well established system is in place. Storage and location sign are established in such that retrieval is very easy and no stock outs& excess materials

3

L3

Preventive actions are in place to avoid stock outs & Excess Materials. Storage methods are standardized. Very good use of colours for identification. Excellent visual control/ application of Shadow board.

4

L4

Every where dirt and every thing is dusty

0

L0

Some equipments, some areas are cleaned regularly. Concept of cleaning is not clear

1

L1

Regular cleaning of all the equipments and other items is in place, but area is not spic & span , Floor broken, water spillages are seen in some areas. Conceptual understanding of cleaning by very few

2

L2

No leakages, no spillages, no dust, floors are spic and span, equipments are clean. Structures are well maintained and painted. Conceptual understanding of celaning is by many

3

L3

Very well established system is in place. All the areas spic and span. Every one follows standards and dust/dirt issues are totally addressed.No leakages & spillages. Conceptual understanding and execution of cleaning by every one

4

L4

0

L0

Standards exist at here and there. Appropriate Displays exist for work place in standard form accessibility/readbility is possible with strain, only few understood & adhere to .

1

L1

SOP exists for all operations (including cleaning activities of rest room, equipments/items ) , Displayed and awareness by some at the work place; all displays in standard form

2

L2

SOP exist for all operations/activities, SOP's are clearly understood by everone and SOP's undergo revision periodically . Efforts towards development of innovative approach to SOP's seen

3

L3

Innovative approach to SOP's ( simple and very easy to understand by everone)/development of innovative training material(pictorial ,regional language) Intricacy of purpose of SOP's are undderstood by everyone

4

L4

No systematic training/adherence to standards (PPE , SOP etc)

0

L0

Some training exists on 5S awareness in a very limited way now and then covering only few section of people

1

L1

Systematic approach to trainings exists covering all section/grades of people; Discipline of adherence to SOP's /PPE's and responsiveness to audit remarks

2

L2

Trainings are effective; People feel pride in maintaing their areas. Self involvement of people in their work area in terms of self audit,trainings , improvement projects etc

3

L3

Systematic approach to Improvement projects; Periodical self audits and appropriate CAPA in place,Demonstration of Pride and ownership of people , efforts to take 5S concepts beyond their boundries

4

L4

No SOP's available / No evidence of internal audits , No check sheets/ Displays not in standard form

Prepared by RISHI GAUTAM

Approved by SUSHIL GUPTA