5S-Lean Audit Checklist--Manufacturing Area Audited / Shift Area Supervisor Employee Interviewed: Audit Team Members Date Performed: 1 Monthly Audit Quarterly Audit Team Self Audit Overall Score XX Sort: Are there any un-needed items in the area? Comments on # 1: Straighten: Do the items that are needed have a conveniently located, visually designated 2 homes? When not in use, are they returned to their home? Comments on # 2: Shine: Are the machines, work stations, floors, walls and all items in the area clean, free from 3 clutter and properly maintained? Are checklists posted and up to date? Comments on # 3: Standardize: Team has established and documented standards on sort, straighten, and shine 4 (checklist). Are current standards being followed, reviewed and improved upon? Comments on # 4: Sustain: Have Sort-Straighten-Shine-Standardize been fully implemented and functioning well? 5 Are past audits posted and used for improvement? Comments on # 5: Visual Controls: Are visual aides in use, up to date and effective in telling how the area is 6 performing, what problems are occurring and what improvements are being made? Comments on # 6: 7 Safety: Are safe work practices in place and being followed. Comments on # 7: Standard Work: Do Standard Work and Work Instructions exist for the area? Are they posted, 8 in use, followed, understood, and updated regularly. Comments on # 8: Continuous Flow: Has continuous flow been established where possible? Does the line move 9 at a steady pace based on Takt? Are standard WIP Levels established and followed? Comments on # 9: Cross training - Job Rotation: Are employees skilled at many different jobs in the area and out. 10 Are these skills documented on a skills matrix? Is there a regular job rotation schedule. Comments on # 10: Quality: Are quality control concepts in place? Is there evidence of defect tracking or other 11 process recording? Are metrics posted? Are defects addressed, not passed on? Comments on #11: Material Flow: Are parts replenished when they are needed, where they are needed in the 12 quantities needed, and presented to the operator as needed without disruption? Comments on # 12: Lean Leadership: Is a Lean Management system in place that utilizes: 1. Leader Standard 13 Work 2. Visual Controls 3. Daily Accountability 4. Discipline. Comments on # 13: Employee Engagement: Are employees actively participating in continuous improvement 14 efforts (5S team, idea boards, root cause for variation, DLS workshops, update SW, ect)? Comments on # 14: Other Lean Tools or General Comments? Are there other Lean Concepts, principles or tools 15 have been implemented in the area? How have these tools improved performance? Comments on #15: 0 1 Score 2 3 ore 4 5 5S-Lean Audit Checklist--GUIDELINES Scoring Key: NA = Not applicable to this area (do not count in total possible score) 0 = No Evidence of implementation. 1 = Some Evidence but major gaps. 2 = Implemented and conforming in about 1/2 of the areas where applicable. 3 = Established and conforming in most areas with some gaps, little or no improvement activities. 4 = Only a Few Minor Gaps Remain and good improvement efforts & use of other Lean tools. 5 = Excellent 5S-Lean Conformance with Substantial Improvement Activities with Employee Involvement. Audit Team: Refer to details below for explanation of each question. If further clarification or examples are needed ask supervisors or lean coordinator. The audit is a too for improvement so include clear comments and conduct employee interviews to understand what has been done and why. Comments: Include specific gaps, exceptional and below standard examples as well as ideas for improvement. Employee Interview (EI): Interview an employee or two from the area to better understand how Lean & 5S are working in the area. (You do not need to ask all questions, just when you need to get a better understanding of where they are.) Audited Team: Corrective Action should be taken for scores of 0 or 1. Consider all suggestions and ideas. 1. Sort 2. Straighten Do items in the area have a designated home? Are they visually (labeled, color coded, shadow boards, etc) and conveniently organized? Can you tell what goes where? EI: What part, tool or paperwork do you spend the most time looking for or walking to while doing your job? Is there a way to decrease that time? 3. Shine Is the entire area clean? Are machines and workstations clean, properly maintained, and have all safety features in place? Do employees understand their role in 5S and TPM (autonomous maintenance)? EI: When is the last time you cleaned: (pick an item or area) ? How did you know it was time to clean it? 4. Standardize Has the team established and documented procedures for: 5S Checklists, Sort Criteria, Straighten Criteria, Red Tag System, Team Meetings, and Peer audits? Are they following the documented procedures? Are the 5S Checklists, Team Binder and visuals organized and up to date? EI: Where is your (name a document) & how do you use it? 5. Sustain 6. Visual Controls Are team members continuously improving their area or at least sustaining previous improvements? Were corrective actions taken on low scores from previous audits? EI: Can you point out an improvement made by your team in the last month? How did it come about? How has it helped? Could it be improved? Are visual aides in use, up to date and effective in telling how the area is performing? Are their goals, actual performance, reasons for variation, and corrective actions visible, up to date and used as an operational tool? EI: Which visual controls in your area do you use? Why? How often? What do they tell you? 7. Safety Are aisle ways, exits, electrical panels fire extinguishers, MSDS, First Aid, etc clearly marked, free from obstructions and trip hazards. Are chemicals properly stored & labeled? PPE & safe practices used? Emergency procedures known? EI: Emergency procedures known (Tornado Shelters, Fire Procedures, etc), MSDS? 8. Standard Work 9. Continuous Flow Do Standard Work and Work Instructions exist for the area? Are they posted, in use, followed, understood, and updated regularly. EI: What are your responsibilities, and the best practices for completing the job safely with high quality and efficiency? Has continuous flow been established where possible? Does the line (all work stations) move at a steady pace based on Takt? Are standard WIP Levels established and followed? EI: What is your Takt Time, # of operators and hours worked to reach your goal? How does that change when customer demand fluctuates? 10. Training-Rotation 12. Material Flow Is a cross training and job rotation program in place within the department and other departments? Is the skills matrix utilized effectively to track training and skill levels of employees within and outside the department? EI: How often do you rotate to other jobs? Is training effective-sufficient? 11. Qualitycontrol concepts in place? Is there Are quality evidence of Six Sigma, defect tracking, error proofing, root cause analysis or other problem solving? Are results (metrics) posted or communicated back to employees? Is there an "Andon" system to respond to problems and discipline to prevent passing on defects? EI. If you discover a defect in your area, what do you do, then what happens? Do defects get passed on? 13. Lean Leadership 14. Employee Engagement 15. Other Lean Tools Do crew leaders and supervisors for the area demonstrate good Lean Leadership? EI. Do your leaders conduct start up meetings, gemba walks, review visual controls, utilize leader standard work, communicate expectations, hold team accountable and have the discipline to sustain efforts? Are employees actively participating in 5S, daily Kaizen, problem solving, DLS Workshops, the Idea Board program or other ways to help their team continuously improve? Is there evidence of recent improvements? EI: What is the most recent improvement made by your team? How has it worked? What remains to be done? Were you involved? What is next? Are there other Lean Concepts, principles or tools implemented. EI: Are there any examples in your area of using: Set Up Reduction, TPM, Six Sigma, Root Cause Analysis, Value Stream or Process Mapping, Daily Accountability, DLS Workshops (Kaizen), A-3 thinking, Teamwork, Error Proofing, Discipline, Knowledge Share, Kanban, Pull Systems? Are there any un-needed items in the area (Tools, parts, drawings, paperwork, tables, fixtures, etc)? Pick any object in the area and question a team member. Employee Interview (EI): What is it for? How often do you use it? Where is it's home? Need to be Red-tagged? Has a Plan For Every Part (PFEP) been established? Is it visually obvious how, how many, when, where and by who the parts will be replenishing? Are parts presented to the operators where they are needed? Can parts be replenished by the materials group without disrupting work? EI: How are your parts replenished? When? By who? What is Kanban and your role in helping it to function properly? standard work, communicate expectations, hold team accountable and have the discipline to sustain efforts? recent improvement made by your team? How has it worked? What remains to be done? Were you involved? What is next? Workshops (Kaizen), A-3 thinking, Teamwork, Error Proofing, Discipline, Knowledge Share, Kanban, Pull Systems? DMAIC Planning Worksheet Project Name: Problem Statement: (Summarize) Business Unit: Sponsor: Process Owner: Business Case Impact: MBB: Other Team Information: Team Members BB: Date Time Att. No. Date Time Att. No. Date Time Att. No. Date Time Meetings No. Schedule ( Planned Actual ) Dy / Wk / Mo Schedule of Activities Define Measure Analyze Improve Control Note: Place an asterisk (*) on review and presentation date(s). Revision # Att.
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