area/facility:kaizen type: kaizen #: date: product:filled out by: rating leveldate level 4 level 3...

Area/Facility: Kaizen Type: Kaizen #: Date:

Product: Filled Out By:

Rating Level Date Date Date Date Date

Level 4

Level 3

Level 2

Level 1

Level 0 No Problems

Waste is anything other than the minimum amount of equipment, materials, parts, space,

and worker's time which are absolutelyessential to add value to the product.

Number of Problems

4 or more

3

Category Item Level

2

1

Organize and label, set boundaries and limits

Sort Eliminate the clutter, sort out what is not neededExcess/unneeded equipment, tools, furniture are in areaUnneeded/outdated items are on walls, bulletin boards, etc.

When in doubt, sort it out!

Store

Floors, walls, stairs, and surfaces are dirty, oily, and/or greasyEquipment is dirty, oily, and/or greasy

Correct places for items are not clearly marked and/or labeledItems are not marked and/or labeled with "return addresses"

Aisle ways, workplaces, equipment locations are not marked

Items are not put away immediately after use

A place for everything and everything in its place!

ShineHeight and quantity limits are not clearly marked

Clean everything inside and out

Items are present in aisle ways, stairways, corners, etc.

Excess/unneeded inventory, supplies, parts, or materials are in areaSafety hazards (water, oil, chemical, machines) exist

Inspection through cleaning!

Standards to maintain sort and set-in-order do not existChecklists for all cleaning and maintenance jobs do not existStandards are not visible in the area and known to area stakeholders

Standardize

Everything in a state of readiness!

Appropriate cleaning materials are not available in the areaLines, labels, signs, etc. are dirty, broken and/or hard to seeOther cleaning problems (of any kind) are present

Keep checklists and standards to maintain the first 3 S's

Total

Daily 5S was not done this weekPersonal belongings can not be easily stored5S checklists/standards are not available or up to dateDaily 5S audits have not been done this week

Self-Discipline/Sustain

Training, reinforcement and measurement

Quantities and limits can not easily be seenItems needed to do job function can't be located in 30 seconds

Maintain discipline through systems and a supportive culture

Workers in area have not been trained in 5S

5S Workplace Audit

How to use a 5S Workplace Audit

User of the Form: Kaizen Team

Customer of the Form: Kaizen Team, Area Associates, Management

Procedure:

1. O

2. O

3. O

Area/Facility: Fabrication Kaizen Type: 5S Kaizen #: 1 Date: 12/23/03

Product: All Filled Out By: Sara, Kaizen team member

Date Date Date Date Date

4 23 24 32 22 1

Level 4

Level 3

No Problems

Level

Level 2

Level 1

1/1

4/0

4 B

1/1

4/0

4 A

Safety hazards (water, oil, chemical, machines) exist

Eliminate the clutter, sort out what is not needed

Level 0

Category

Sort

Item

Unneeded/outdated items are on walls, bulletin boards, etc.Items are present in aisle ways, stairways, corners, etc.

Excess/unneeded inventory, supplies, parts, or materials are in area

When in doubt, sort it out!

Excess/unneeded equipment, tools, furniture are in area

Waste is anything other than the minimum amount of equipment, materials, parts, space,

and worker's time which are absolutely essential to add value to the product.

Number of Problems

4 or more

3

2

1

Purpose: To record scores for the five categories of 5S and general target scores for the area. The scores show how well the area is doing in terms of 5S status--a passing score is 20 or lower, with no score higher than a 2. Ratings are done before and after 5S events to show progress. This audit will be posted as part of the Workplace Display. Highlights from this form can be used on the Continuous Improvement Billboard, and this form can also be used as is or modified as part of an ongoing 5S Audit Program.

Enter the date when the rating is done in a date box in the upper part of the form. When rating s are done before and after a 5S event

in one day, indicate before with a "B" and after with an "A" in the date boxes.

In the "Level" boxes, enter a rating level for each of the 25 rating categories. Use the rating definition key in the upper left part of the

form to determine rating levels according to the number of problems observed.

Add up the ratings and enter the sum in the "Total" box at the bottom of the "Level" column.

Rating Level

5S Workplace Audit