1s 2s Audit Checklist | 1s 2s Audit Check Sheet

5S is an improvement process to eliminate waste that originates from a poorly organized workplace/area. It is the basic tool and foundation stone of Lean manufacturing, TPM, TQM, or any organizational process improvement activity. Without 5S practice, an organization cannot succeed in improving the product & process quality. This article lists 1S, 2S, and 3S audit points along with 1S 2S audit checklist sample.

5S full form in Japanese and English language

1. Seiri or Sorting out
2. Seiton or Set in Order or Organize
3. Seiso or Shine or Sweep
4. Seiketsu or Standardize
5. Shitsuke or Sustain or Self Discipline

1s 2s Audit Checklist

1s Audit Checklist

1S Meaning: Seiri – Sorting Out (Disposal of unwanted items)

It helps to segregate necessary & unnecessary items and eliminates unwanted items.

1. Unwanted (unidentified) items not to be on the Floor (a scrap of paper, tools, parts, bins, chips, oil, etc.).  Nothing on the top of the rack, under the table, under/behind the machine, between the Machines & similar places, etc.
2. Disposal System: Old drums, Grinding Sludge, Paint Sludge, used oil, used consumables, Welding rods, cutting tools, electric wires, R/M end pieces, Scrap, Hazardous waste, etc. are disposed off at regular intervals.   
3. No storage of unused/ excess parts like raw material, bought-out parts, finished goods, etc., Hold material waiting for decision (rejection, rework).
4. No storage of old machines, equipment, old standards (not in use), old drawings/parts/documents (obsolete), not-in-use items like old furniture, old racks, material handling equipment, old equipment, or utility items inside the factory premise.
5. No mix-up of different types of parts, No mix-up of OK (wanted), Rejected (unwanted) Parts, Rusty & dusty material, no broken bins, hardware/tools mixing, machine accessories, maintenance spares, Red bins on all machines & daily clearance.

1s audit checklist with scoring criteria:

2s Audit Checklist

2S Meaning: Seiton – Set in Order – Organize – Systematic Arrangement

This step essentially means arranging items in a systematic way, for easy accessibility and using them in the best order.

1. “There is a place for everything & everything is in its place”. Locations for the storage of the parts, Documents, tools, equipment / Machine & spares, etc. are clearly defined with Visuals. Route card & Identification tags on all Parts.
2. Bin/parts Arrangement in bin & trolleys etc. (No zig-zag placing & no different type of bins each other inside / Top). The right component in the right containers/pallets/ Bins/ Trolleys etc.
3. Gangways are clearly marked (no zig-zag movement of man & material),  Gangways & Jogging track (wall side) are free of material/bins, Outside area should be clear, no jam. trolleys, bins, parts etc.
4. Availability of Work Standard/Control plan & PFD, Daily machine check sheet, setup approval part availability,  in-process report, WI, Gauges, Machine data sheet, and data display boards are available & updated.
5. 5S zones are marked, roles and responsibilities are defined, and zone-specified documents (1S/2S score, Skill matrix, Safety chart, etc.) are updated and maintained. 

2s audit checklist with scoring criteria:

3s Audit Checklist

3S Meaning: Seiso – Shine – Sweep (Shine everything-cleaning.)

This step makes the workplace neat & clean by eliminating dirt, dust & other foreign matter.

1. Almirah, racks drawers, cupboards,  tables, fans, and lights are visible and clean, window glass, machines, machines spares, Jig/Fixture, Tools/Dies, and Containers/pallets are clean and free from damage.
2. No documents are pasted on walls, glasses, or machines. No gum/tape adhesive marks on glasses, walls & machines.
3. Machines are Clean & Clear (scrap, leakages of water, oil, gas, air, coolant, etc.). Machine CLIT activities are done as per the daily machine checklist, material handling equipment is clean, Jigs & Fixtures, and Gauges are clean, and free from dust & damage.

3s audit checklist with scoring criteria:

Other Safety Checkpoints

1. PPEs Use ( Shoes, Gloves, Goggles etc.). No Floor damage or fire extinguishers are available.
2. No Loose Wiring & Pipe.
3. No M/C cover & panel open.
4. Safety guard on moving parts.