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5 S – Manufacturing Audit

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5 S – Manufacturing Audit

  1. 1. 5S – Manufacturing Audit 5S – Improvement Questionnaire Anand Subramaniam
  2. 2. <ul><li>“Everything can be improved.&quot; </li></ul><ul><ul><li>- C. W. Barron </li></ul></ul>
  3. 3. 5 S – Focus Sort Focus &quot;If in doubt throw it out‘ Store Focus 7 Waste Shine Focus Who, What, When, Why, Where & How Standardise Focus Standard Process & Make Work Easier Sustain Focus Ongoing Performance Improvement
  4. 4. Sort & Discard <ul><li>Is uncontrolled personal equipment or belongings in the direct work areas? (eg coats on chairs) </li></ul><ul><li>Is there discarded Personal Protective Equipment within the area? </li></ul>5 <ul><li>Is it obvious which items are marked as unnecessary. Has a &quot;Red Tag&quot; exercise or similar been conducted or recently concluded? </li></ul>4 <ul><li>Are notice boards or similar current with regard to content ? </li></ul><ul><li>Is there duplication of information in individuals work area? </li></ul><ul><li>Are there items in the area which require archiving or have exceeded there lifetime? </li></ul>3 <ul><li>Are there any obsolete or superseded machines, equipment, tooling (e.g. jigs & dies) within the area? </li></ul><ul><li>Are there production materials & parts (inc samples) that are not applicable to this process or that should have been removed? </li></ul>2 <ul><li>Are there items such as obsolete or unused signage & documentation on walls, floors, ceilings within the area? </li></ul>1
  5. 5. Store & Make Safe <ul><li>Are appropriate facilities provided to store personal equipment away from the workspace that is both safe & where necessary accessible? </li></ul><ul><li>Are facilities provided for the control/display of items in an individuals work area? </li></ul>10 <ul><li>Are shelves & other storage areas (e.g. racks, cabinets, floors) clearly identified as to their content. Do these identifications indicate what goes where? </li></ul><ul><li>Do locations for storage have owners? </li></ul>9 <ul><li>Are files & other media arranged in a manner that ensures repetition of storage with no duplication? Is it clear which items are in use? </li></ul><ul><li>Is there a process to ensure that archived documentation or similar is readily retrievable? (inc electronic media) </li></ul>8 <ul><li>Is equipment, tooling (e.g. jigs & dies) & materials arranged rationally to assist with use & retrieval? </li></ul><ul><li>Are the maximum & minimum allowable quantities of materials, parts or consumables indicated. (consider KanBan)? </li></ul>7 <ul><li>Is there a 5S map or layout for the work area that clearly identifies the workplace geography including: walkways, processes, storage, personnel, contact details, desks, equipment, recycling, information areas etc. (consider floor marks, barriers) </li></ul>6
  6. 6. Shine & Eliminate Waste <ul><li>Do persons habitually clean there area without being told? </li></ul><ul><li>Are personal waste bins allowed to overflow? </li></ul>15 <ul><li>Are Floor areas clean, undamaged (e.g. shiny) without slip, trip, or quality hazard? Include underneath equipment & machines. Consider the effects of water, oil, waste, holes, cables etc. </li></ul>14 <ul><li>Are information areas & notice boards kept up to date, orderly & regularly reviewed? </li></ul><ul><li>Are document expiry times shown? </li></ul><ul><li>Are owners of information displays known & obvious? Is there a system to ensure that these items are maintained? </li></ul>13 <ul><li>Is equipment, machines & tooling kept free from debris & oil (inside & out)? </li></ul><ul><li>Is Work in Progress, Kan Bans, and other associated materials kept in a manner that does not allow contamination of dirt or other materials (including parts)? </li></ul>12 <ul><li>Are the schedules & responsibilities defined for the cleaning & checking of the area to promote workplace organisation & improvement? </li></ul><ul><li>Is there a policy to promote sharing of tasks & individual involvement in the process? </li></ul>11
  7. 7. Standardise & Improve Performance <ul><li>Do people have work ware which is clean & undamaged? </li></ul><ul><li>Does work ware promote belonging and a Team methodology? </li></ul><ul><li>Is Personal Protective Equipment worn as prescribed? </li></ul>20 <ul><li>Are the first 3S being maintained? </li></ul><ul><li>Are we operating within the rules that we set & agreed? </li></ul>19 <ul><li>Is there a clear & visual improvement plan that drives performance improvement? </li></ul><ul><li>Are associated measures visual. Is the story of the area told? </li></ul>18 <ul><li>Is the climate set to provide suitable work conditions such as temperature, humidity & lighting. Is the area ventilated well enough to be clear of heavy dust & odours, (clean to breath). </li></ul><ul><li>Is the angle & intensity of light adequate for the work being done? </li></ul>17 <ul><li>Is the workplace visual in its control methods, are these methods easy to understand & follow, are they standard in appearance ? </li></ul><ul><li>Are Information Centres or Team Boards used as a focal point for information. Do these promote Team ethos? </li></ul>16
  8. 8. Sustain through PDCA <ul><li>Are the team proactive in the management of the workplace & its environment. </li></ul><ul><li>Are all the Team compliant in the agreed rules ? </li></ul><ul><li>Are targets agreed & achieved by the team as planned? </li></ul><ul><li>Does the Team assemble for activities at the agreed time & place? </li></ul>25 <ul><li>Is the standard for visual control common across all 5S areas? </li></ul><ul><li>Are fonts, styles, identifications, reports, naming conventions, maps, colour schemes, corporate identity, lighting etc, appropriately styled? </li></ul>24 <ul><li>Are Team Activity Boards & Information Centres up to date & regularly reviewed? </li></ul>23 <ul><li>Are tools, equipment, materials and information being stored correctly? </li></ul>22 <ul><li>Are people within the area trained in key procedures & practices? This includes 5S principles. </li></ul><ul><li>Are procedures up to date & regularly reviewed? </li></ul>21
  9. 9. <ul><li>“One of the rarest things that a man ever does, is to do the best he can.&quot; </li></ul><ul><ul><li>- Josh Billings </li></ul></ul>
  10. 10. <ul><li>Good Luck </li></ul><ul><li>http://www.linkedin.com/in/anandsubramaniam </li></ul>