Professional Documents
Culture Documents
Auditor
Rev.No-00
Ver.No-00
Date-07.04.2014
Audit Zone :
Audit Date
5S - ShitsukeSustain (Discipline)
4S - SeiketsuStandardise
1S - Seiri -Sorting
S.No
Check Item
Max
Rejected Materials, Rework materials, waste materials, obsolete items, shelf life expired,
Unnecessary
damaged items, old records , obsolete documents etc, are regularly identified and removed
items/Materials/ Documents
from place of work and timely disposed off. Red tag system in place.
Machines, Equipments,
spare parts etc.
Unusable machine parts, motors, Equipment, trolleys, Paint guns are identified periodically as
a system, removed from place of work and disposed off regularly.
Broken or unusable Tools, accessories, fixtures are timely identified, repaired if possible for
reuse or disposed off on regular basis.
Used Items/surroundings
Empty LPG cylinders, CO2 cylinders, O2 Cylinders Argon Cylinders, N2 Cylinders, Paint tins,Oil
drums, Packaging materials, Weld Coils, Thinner, Ecosol, Kerosene and other used items are
regularly removed from the plant and disposed off regularly.
Excess parts/Materials
(Usable)
Tubes, Rods in cutting section, Excess of spare parts/Materials/Stationary items in shop are not
kept in the place of use and taken steps regularly to prevent excess inventory of these items.
Layout/Yellow/
White/Red lines
Dividing lines are clearly drawn with Yellow/ white lines on the floor. Red lines are drawn for
storage of rejects/Scrap/Waste materials
Shelves, Lockers,
drawers
Required items are clearly identified and are stored in the departments, Tool crib and
Stationary items etc are stored with shadow board concept. Items near machine are identified
& stored in pallets/ in bins with appropriate labels.
Storage Methods
Location Charts
Orderliness
Floors
Components are stored in Bins, pallets and trolleys in shop floor with appropriate labels. The
items are stored based on the frequency of the usage & size. Nothing on floor concept is
evident
Items are earmarked with Tags. Materials under inspection /Rejections are stored in such a way
that they are not allowed to get mixed up and clearly identified with stickers. Item wise
location charts are displayed prominently.
All items are arranged in a orderly manner and tagged with part numbers with visual control
Floors are being swept regularly and kept spic & span. Broken floors are cemented.
Water cleaning is done in Assembly floors, toilets, office rooms with detergent regularly.
4
4
4
Machines/
Equipments/ Computer
Peripherals
Machine cleaning & inspection by operator. Handling equipments are cleaned by the
respective drivers. Overhead cranes are cleaned regularly. Computer peripherals are cleaned
by users regularly.
Spills, Leakages
Oil, coolants, grease, cleaning agents, paints are not allowed to spill. In case happens
immediately attended. No leakage from water taps, air hoses, oil drums etc.
No cobweb, no dust is allowed on the walls / roofs/ windows & being cleaned regularly.
Standards/
Operating Procedures /
Displays
The standards/operating procedures related to operations and house keeping are established
with clarity and are displayed in place of use.. Displays are in standard form
Hazardous
Materials/Shelf life items
Hazardous chemicals in the plant & shelf life items are stored separately under stipulated
conditions .Safety sinages displayed instruction are in commuincable form.
Disinfections
No over flowing of sewage, water logging /stagnation in canals, no leakage of roofs etc. in the
work areas.
Adequate ventilation, lighting being maintained. Temperature and humidity in work areas are
comfortable.
4
5
1
2
3
4
5
Prepared by
Team BE
Work environment
4
4
4
4
4
4
Every body in department is trained in 5S awareness,SOP's and safety methods and retrained
whenever required.
Every one adheres to SOP's /appropriate PPE's and ensures others also follows wherever
required
Team's Responsiveness
Response to last audit observations through appropriate CAPA, Carryout self audits and
corrections ; Egarness to learn and adopt
Regular reviews by HOD; Demonstration of "This is my workplace . I will maintain it spic and
span" Efforts seen to take these systems beyond boundaries
Continual Improvements
Ownership & pride
Approved by
Head BE
Total
100
Actual
BALCO Limited
5S Audit Check List - Scoring Guidelines
Following are guide lines for trained internal auditors to allocate score for the audited zones. Internal auditors to compare actual status with the observed status as
described below for each of the evaluation of 5S elements. Auditors to take close comparison and then do the scoring. In case of the actual status falls in between two
levels say for example Level 0 and Level 1 then auditors can give score points like 0.2, 0.4,0.6,0.8 what the auditors feel more appropriate. It is only auditors discretion
1S - Seiri -Sorting
Observed Status
Score
Level
Clutterd. No regular sorting out & disposal of excess materials, unwanted items& expired documents
L0
Some unwanted, excess materials sorted out once a while and disposed.
L1
System exists for disposal of process scrap and waste materials, but needs improvement in all other areas.
L2
A well established system is in place of clearing regularly unwanted items, excess items and documents, but delay
indispose of excess items
L3
Very well established system is in place and standards are being followed by all regularly. Preventive actions are in place to
avoidaccumulation of excess materials, unwanted items & expressed documents.
L4
No orderly arrangement of items .Too much time taken for locating & issuing items
L0
Some signs /displays / organized way of arrangement of items at few places /locations
L1
Systematic arrangement in many areas. Yellow/ Red/ White lines are drawn. Visual control labels are seen in few places to
control inventory and prevent stock outs
L2
A well established system is in place. Storage and location sign are established in such that retrieval is very easy and no
stock outs& excess materials
L3
Preventive actions are in place to avoid stock outs & Excess Materials. Storage methods are standardized. Very good use of
colours for identification. Excellent visual control/ application of Shadow board.
L4
L0
Some equipments, some areas are cleaned regularly. Concept of cleaning is not clear
L1
Regular cleaning of all the equipments and other items is in place, but area is not spic & span , Floor broken, Oil/water
spillages are seen in some areas. Conceptual understanding of cleaning by very few
L2
No leakages, no spillages, no dust, floors are spic and span, equipments are clean. Structures are well maintained and
painted. Conceptual understanding of celaning is by many
L3
Very well established system is in place. All the areas spic and span. Every one follows standards and dust/dirt issues are
totally addressed.No leakages & spillages. Conceptual understanding and execution of cleaning by every one
L4
L0
Standards exist at here and there. Appropriate Displays exist for work place in standard form accessibility/readbility is
possible with strain, only few understood & adhere to .
L1
SOP exists for all operations (including cleaning activities of rest room, equipments/items ) , Displayed and awareness by
some at the work place; all displays in standard form
L2
SOP exist for all operations/activities, SOP's are clearly understood by everone and SOP's undergo revision periodically .
Efforts towards development of innovative approach to SOP's seen
L3
Innovative approach to SOP's ( simple and very easy to understand by everone)/development of innovative training
material(pictorial ,regional language) Intricacy of purpose of SOP's are undderstood by everyone
L4
L0
Some training exists on 5S awareness in a very limited way now and then covering only few section of people
L1
Systematic approach to trainings exists covering all section/grades of people; Discipline of adherence to SOP's /PPE's and
responsiveness to audit remarks
L2
Trainings are effective; People feel pride in maintaing their areas. Self involvement of people in their work area in terms of
self audit,trainings , improvement projects etc
L3
Systematic approach to Improvement projects; Periodical self audits and appropriate CAPA in place,Demonstration of Pride
and ownership of people , efforts to take 5S concepts beyond their boundries
L4
5S - ShitsukeSustain (Discipline)
4S - SeiketsuStandardise
No SOP's available / No evidence of internal audits , No check sheets/ Displays not in standard form
Prepared by
Team BE
Approved by
Head BE