1s 2s Audit Checklist

5S is an improvement process to eliminate the waste that originates from a poorly organized workplace/area. It is the basic tool and foundation stone of a Lean manufacturing, TPM, TQM or any process improvement activity within an organization. Without 5S practice, an organization cannot succeed in improving the product & process quality.

Table of Contents

5S full form in Japanese and English language

Seiri or Sorting out
Seiton or Set in Order or Organize
Seiso or Shine or Sweep
Seiketsu or Standardize
Shitsuke or Sustain or Self Discipline

1s Audit Checklist

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

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

Unwanted (unidentified) items not to be on Floor (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.
Disposal System: Old drums, Grinding Sludge, Paint Sludge, used oil, used consumables, Welding rod, cutting tools, electric wires, R/M end piece, Scrap, Hazardous waste etc. is disposed off at a regular interval.
No storage of unused/ excess parts like raw material, bought out parts, finished goods etc., Hold Material waiting for decision (rejection, rework).
No storage of old machines , equipment’s, old standards (not in use) , old drawings/parts/documents (obsolete), not in use items like old furniture, old racks, material handling equipments, old equipments, utility items inside the factory premise.
No Mix up of different type 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.

“There is a Place for every thing & Every thing is in its place”. Locations for storage of the parts, Documents, tools , equipment / Machine & spares etc. are clearly defined with Visuals. Route card & Identification tags on all Parts.
Bin / parts Arrangement in Bin’s & trolleys etc. (No zig zag placing & no different type of bins each other inside / Top). Right component in right containers/pallets/ Bins/ Trolleys etc.
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.
Availability of Work Standard/Control plan & PFD, Daily machine check sheet, setup approval part availability, in-process report, WI, Gauges, Machine data sheet, Data display boards are available & updated.
5S Zones are marked, Roles and Responsibilities are defined, 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.

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

3s audit checklist with scoring criteria:

Other Safety Check points

PPEs Use ( Shoes, Gloves, Goggles etc.). No Floor damage, Fire extinguisher are available.
No Loose Wiring & Pipe.
No M/C cover & panel open.
Safety guard on moving parts.