5S Audit Checklist for Manufacturing Companies by Operational Excellence Consulting

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[Note: This is a partial preview. To download this presentation/checklist, visit: https://www.oeconsulting.com.sg/training-presentations] This is a 5S audit checklist for manufacturing companies. There are a total of 25 evaluation criteria spanning the 5S principles. Each criteria is evaluated against a five-point scale (0=we constantly deviate; 4=flawless, no deviations ever). The maximum possible score is 100 (25 questions x 4 points) organized into five scoring bands: 81-100: Excellent 61-80: Good 41-60: Fair 21-40: Poor 1-20: Very Poor This 5S audit worksheet can be applied generally to all manufacturing departments. You may change the audit criteria to suit your specific environment. With the 5S Excel worksheet, you can instantly view your monthly 5S audit results visually with a Radar Chart and a Monthly Trend Chart. Start auditing your shopfloor 5S performance today and map out an actionable plan based on the audit findings! CONTENTS 1. Summary of 5S Principles 2. 5S Audit Checklist To download this complete checklist, visit: http://www.oeconsulting.com.sg

Business

© Operational Excellence Consulting. All rights reserved.
5S Audit Checklist
for Manufacturing Companies
5S Audit Checklist for the Evaluation of
Manufacturing Companies
This audit form consists of 25 performance criteria based on the 5S
principles for the evaluation of manufacturing companies.

© Operational Excellence Consulting. All rights reserved. 2
Contents
Summary of 5S Principles
5S Audit Checklist
1
2
NOTE: This is a PARTIAL PREVIEW. To
download the complete presentation, please visit:
http://www.oeconsulting.com.sg

© Operational Excellence Consulting. All rights reserved. 4
5S Principles
Sort
Set In OrderShine
Standardize
Sustain

© Operational Excellence Consulting. All rights reserved. 5
What is 5S?
Principles General Description
1S Sort
Remove what is not needed and keep
what is needed
2S Set in Order
Arrange essential items in order for
easy access
3S Shine
Keep things clean and tidy; no trash or
dirt in the workplace
4S Standardize
Establish standards and guidelines to
maintain a clean workplace
5S Sustain
Make 5S a habit and teach others to
adhere to established standards

© Operational Excellence Consulting. All rights reserved. 7
5S Audit Scoring
0 4321
We constantly
deviate
Flawless, no
deviations ever
For each audit or evaluation criteria in the next five slides,
assign a score from 0 to 4:
There are a total of 25 questions. You may change the questions
to suit your workplace environment.
The maximum possible score is 100.

© Operational Excellence Consulting. All rights reserved. 8
5S Audit Checklist
1S: SORT Score
1
Unneeded equipment, tools, furniture, etc. are
present. 0 1 2 3 4
2
Unneeded items are on walls, notice boards,
etc. 0 1 2 3 4
3
Items are present in walkways, stairways,
corners, fire exits etc. 0 1 2 3 4
4
Unneeded inventory, supplies, parts, or
materials are present. 0 1 2 3 4
5
Safety hazards (water, oil, chemical, machines)
exist. 0 1 2 3 4
Sum 1st S:

© Operational Excellence Consulting. All rights reserved. 9
5S Audit Checklist
3S: SHINE Score
11
Floors, walls stairs, and surfaces are free of
dirt, oil, and grease. 0 1 2 3 4
12
Equipment is not kept clean and free of dirt, oil,
and grease. 0 1 2 3 4
13 Cleaning materials are not easily accessible. 0 1 2 3 4
14
Lines, labels, signs, etc. are not clean and
unbroken. 0 1 2 3 4
15
Other cleaning problems of any kind are
present. 0 1 2 3 4
Sum 3rd S:

© Operational Excellence Consulting. All rights reserved. 10
5S Audit Checklist
5S: SUSTAIN Score
21
How many workers understand the 5S
principles. 0 1 2 3 4
22
How many times last week was daily 5S not
performed. 0 1 2 3 4
23
Number of times that personal belongings are
not neatly stored. 0 1 2 3 4
24
Number of times job aids are not available or
up to date. 0 1 2 3 4
25
Number of times last week daily 5S inspection
were not performed. 0 1 2 3 4
Sum 5th S:
Sum of all S’s:

© Operational Excellence Consulting. All rights reserved. 11
Score Meter Example
720
85
Area: Machining Department
5S Rating : Excellent
Last Updated : Dec 22th, 2016
Comments: Keep up the good work!
Very Poor Poor Fair Good Excellent
1 20 40 60 80 100

© Operational Excellence Consulting. All rights reserved. 12
Radar Chart of 5S Performance
0
5
10
15
20
Sort
Set In Order
ShineStandardize
Sustain
Monthly 5S Performance

© Operational Excellence Consulting. All rights reserved. 13
5S Monthly Trend Performance
0
10
20
30
40
50
60
70
80
90
100
Jan-16 Feb Apr May Jun Jul Aug Sep Oct Dec
2016 Monthly Audit Results
Score Goal

© Operational Excellence Consulting. All rights reserved. 14
5S Audit Checklist & Results

© Operational Excellence Consulting. All rights reserved.
About
Operational Excellence
Consulting

© Operational Excellence Consulting. All rights reserved. 16
About Operational Excellence
Consulting
• Operational Excellence Consulting is a management
training and consulting firm that assists organizations in
improving business performance and effectiveness.
• The firm’s mission is to create business value for
organizations through innovative operational excellence
management training and consulting solutions.
• OEC takes a unique “beyond the tools” approach to enable
clients develop internal capabilities and cultural
transformation to achieve sustainable world-class excellence
and competitive advantage. For more information, please visit
www.oeconsulting.com.sg

© Operational Excellence Consulting. All rights reserved.
END OF PARTIAL PREVIEW
To download this presentation,
please visit:
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Operational Excellence Consulting

[To download this poster, visit: https://www.oeconsulting.com.sg/training-presentations] Jidoka, a fundamental pillar of Lean manufacturing and the Toyota Production System (TPS), is a concept that revolutionizes how we approach quality control in manufacturing. Derived from Japanese, "Jidoka" translates to "automation with a human touch." It represents a powerful strategy for building quality into the production process, thereby enhancing product quality, reducing waste, and fostering more efficient and reliable manufacturing practices. What is Jidoka? Jidoka is a manufacturing philosophy that seamlessly blends automation and human intervention. It encompasses the automatic detection of problems (automation) and empowers humans to intervene when necessary (autonomy). Benefits to Practitioners of Lean Manufacturing: 1. Improved Product Quality: Jidoka's focus on early defect detection ensures that faulty products are identified and addressed promptly, preventing the production of defective goods. 2. Reduced Waste: By catching defects early in the production process, Jidoka minimizes rework, scrap, and the consumption of additional resources, contributing to waste reduction. 3. Enhanced Efficiency: Jidoka optimizes processes by prioritizing quality over quantity, leading to more streamlined and reliable manufacturing operations. 4. Empowerment of Workers: Jidoka empowers frontline workers by enabling them to take immediate action when issues arise, promoting a culture of continuous improvement. The Four Steps of Jidoka: Jidoka consists of four essential steps, each contributing to its overarching goal of enhancing quality and efficiency: 1. Detect the Abnormality: - Goal: Identify deviations from the standard process. - Key Activities: Implement Poka-yoke devices, use time as a detection mechanism, and employ visual controls like andon and Kanban for immediate problem signaling. 2. Stop Production: - Goal: Halt production immediately upon detecting an abnormality. - Key Activities: Initiate manual or automatic stoppage of the process to prevent the production of defective goods. 3. Fix the Problem at the Source: - Goal: Address the root cause of the issue and ensure production can resume smoothly. - Key Activities: Fix or correct the abnormal condition, implement temporary countermeasures, and make decisions at the lowest possible organizational level. 4. Implement Countermeasures: - Goal: Prevent the recurrence of the abnormality and foster continuous improvement. - Key Activities: Investigate the root cause of the problem, install permanent countermeasures, and prioritize efforts for ongoing process enhancement.

Four Steps of Jidoka Poster

Operational Excellence Consulting

[To download this poster, visit: https://www.oeconsulting.com.sg/training-presentations] The Build-Measure-Learn process is a fundamental concept within the Lean Startup methodology, developed by Eric Ries. It represents an iterative and systematic approach to developing and growing a startup or innovative project. This process prioritizes rapid experimentation, data-driven decision-making, and continuous validation of hypotheses. It consists of three interconnected phases: Build, Measure, and Learn. Benefits: - Efficiency: The Build-Measure-Learn process encourages the creation of a Minimum Viable Product (MVP), which helps startups avoid building elaborate products or services that may not find a market fit. This efficiency conserves resources and minimizes waste. - Risk Mitigation: By releasing an MVP and gathering real-world data early in the development process, startups can identify and address issues, reducing the risk of investing significant time and resources into an unviable idea. - Customer-Centricity: This process places a strong emphasis on understanding customer needs and behaviors. By continuously collecting and analyzing data, startups can tailor their products or strategies to meet customer expectations more effectively. - Iterative Improvement: The iterative nature of Build-Measure-Learn allows for rapid adjustments and refinements based on feedback and insights. Startups can pivot (make significant changes) or persevere (build upon what works) with greater confidence. - Innovation: It fosters a culture of innovation and experimentation within the organization, as teams are encouraged to explore new ideas and adapt to changing market conditions.

Lean Startup: Build-Measure-Learn Process Poster

Operational Excellence Consulting

[To download this poster, visit: https://www.oeconsulting.com.sg/training-presentations] In the dynamic world of marketing, understanding the intricacies of consumer behavior and crafting effective strategies to engage potential customers is paramount. One such invaluable framework that has stood the test of time is the AIDA model. AIDA, which stands for Attention, Interest, Desire, and Action, serves as a foundational cornerstone in the art and science of marketing. Defining AIDA: AIDA represents a carefully structured sequence of stages that individuals traverse on their journey from being unaware of a product or service to becoming active customers. Here's a break down each element: - Attention: This is the inception stage where marketers strive to capture the fleeting attention of their target audience. It's about creating a spark, a momentary pause, amidst the cacophony of information bombarding consumers daily. - Interest: Once attention is secured, marketers delve deeper into engaging the audience. They strive to nurture this initial curiosity into genuine interest by providing relevant information and compelling narratives. - Desire: Building upon interest, the desire stage aims to stoke the flames of want within potential customers. Here, marketers employ persuasive techniques to showcase how their product or service can make a tangible and positive impact on the lives of consumers. - Action: The culmination of the AIDA journey is the action stage. At this point, marketers leverage the accumulated attention, interest, and desire to prompt a specific action from the consumer--typically, making a purchase or taking a significant step towards a brand or product. Benefits of the AIDA Model: The AIDA model offers several benefits to marketers and businesses: - Clarity: It provides a clear and structured framework for understanding the customer journey, allowing marketers to align their efforts accordingly. - Segmentation: AIDA enables marketers to tailor their messaging to different stages of the funnel, ensuring relevance at every point in the customer's decision-making process. - Measurability: By identifying which stage of the funnel needs improvement, marketers can measure the effectiveness of their campaigns and make data-driven adjustments.

AIDA Marketing Model Poster

Operational Excellence Consulting

[Note: To download this poster, visit: https://www.oeconsulting.com.sg/training-presentations] One-Point Lessons stand as a cornerstone activity within an Autonomous Maintenance (AM) program, a vital component of Total Productive Maintenance (TPM). These concise, self-study guides embody the spirit of continuous improvement on the shopfloor. At their core, One-Point Lessons are designed to transfer essential knowledge and skills among team members, enabling them to become autonomous problem-solvers and proactive contributors to operational excellence. However, common mistakes can hinder their effectiveness. Three key errors to avoid include: 1. Insufficient Clarity: Ensuring that the lesson's purpose and content are crystal clear is essential, as unclear lessons can lead to confusion among learners. 2. Information Overload: Overwhelming the audience with excessive data can dilute the lesson's impact and hinder effective learning. 3. Lack of Adaptability: Customizing lessons to address specific workplace needs is crucial. Using generic content without personalization reduces the relevance and effectiveness of the lesson. What Is a One-Point Lesson? A One-Point Lesson is a compact, 5-10 minute learning resource meticulously created by your very own team members. It focuses intensely on a single facet of equipment, machinery, or work processes. These lessons are crafted to offer clarity and simplicity, ensuring that every learner grasps the essential insights required to excel in their roles. Purposes of One-Point Lesson: One-Point Lessons serve three fundamental purposes within the context of Total Productive Maintenance (TPM) and Autonomous Maintenance (AM) programs: - First, they are invaluable tools for sharpening equipment-related knowledge and skills among team members, bridging knowledge gaps, and ensuring that everyone possesses the essential know-how needed for daily production tasks. - Second, One-Point Lessons provide a means to efficiently communicate critical information when it is most needed, enabling proactive problem-solving and reducing downtime. - Finally, these lessons play a pivotal role in enhancing the overall performance of the entire team, fostering a culture of continuous improvement and driving excellence on the shopfloor. The One-Point Lessons Poster include the following: 1. What is a One-Point Lesson? 2. Three Purposes of One-Point Lessons. 3. Three Categories of One-Point Lessons. 4. How to Prepare a One-Point Lesson. 5. Tips for Writing Effective Lessons.

TPM: One-Point Lessons Poster

Operational Excellence Consulting

[To download this poster, visit: https://www.oeconsulting.com.sg/training-presentations] The 4Ms, also known as Man, Method, Machine, and Material, are a systematic framework used in process analysis and improvement across various industries. These four critical elements provide a structured approach to understanding, evaluating, and optimizing processes within an organization. Definition of the 4Ms: - Man: This represents the human element involved in a process or task. It encompasses the skills, knowledge, training, and experience of individuals performing the work. - Method: Method refers to the procedures, techniques, and processes used to complete a task or achieve a specific goal. It examines how work is organized and executed. - Machine: Machine includes the equipment, tools, technology, and machinery used in a process. This category covers both hardware and software components essential to the operation. - Material: Material involves the raw materials, components, and resources required to produce a product or deliver a service. It also considers the quality and availability of materials. The 4M Framework poster is available in two distinct themes: a vibrant color scheme and a professional monochrome version. In both formats, the poster comes in a convenient PDF as well as an editable PPTX format, enabling effortless printing on A3/A4-sized paper from standard office copier machines. This versatile resource can be prominently displayed on employee workstations or distributed alongside problem solving training materials. Furthermore, the 4M Framework poster is an ideal supplement to Lean-related training presentations. It serves as a valuable takeaway, summarizing the core principles of problem solving and root cause analysis and reinforcing the key takeaways from your training.

4M Analysis Poster

Operational Excellence Consulting

[To download this poster, visit: https://www.oeconsulting.com.sg/training-presentations] Hoshin Planning, also known as Hoshin Kanri or Policy Deployment, is a strategic management methodology that empowers organizations to set and achieve their annual goals collaboratively. It involves the alignment of objectives across departments, emphasizing both process improvements and desired outcomes. Senior management leads the development of these goals in consultation with their subordinates, fostering a culture of shared vision and accountability. Hoshin Planning offers a comprehensive approach to strategic management that yields several key benefits. It ensures strategic alignment throughout the organization, enhances focus on critical objectives, fosters a culture of accountability, promotes continuous improvement, and maintains transparent monitoring of progress. This methodology also encourages learning and growth through the evaluation of successes and failures, eliminates inefficiencies, and ultimately enhances organizational efficiency and effectiveness. This poster serves as a visual reminder of the Hoshin Planning process and the valuable benefits it brings to organizations seeking strategic alignment and sustained improvement. The Four Phases of Hoshin Planning poster is available in two distinct themes: a vibrant color scheme and a professional monochrome version. In both formats, the poster comes in a convenient PDF as well as an editable PPTX format, enabling effortless printing on A3/A4-sized paper from standard office copier machines. This versatile resource can be prominently displayed on employee workstations or distributed alongside Hoshin Planning training materials. Furthermore, the Hoshin Planning poster is an ideal supplement to Lean-related training presentations. It serves as a valuable takeaway, summarizing the core principles of Hoshin Planning and reinforcing the key takeaways from your training.

Hoshin Planning Poster

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Organisational success today depends on effective communication and collaboration with individuals from cultures with varying beliefs and practices. Indeed, with the workforce increasingly comprised of people of varying cultural backgrounds, leaders must now prioritise the significance of cultural competence in the workplace. Ensuring cultural competence at every level of your organisation cannot be understated. While cultural disparities can manifest in different ways, as a leader, you must build deep and nuanced cultural competence skills and education to accurately spot, address and alleviate the various scenarios that can arise. Failing to recognise the importance of cultural competence or not acting to improve it can lead to cultural negligence. There are a few things to consider to ensure your organisation is on the right track. In this deck, you'll understand the importance of building cultural competence in the workplace. You'll also learn • The three (3) dimensions of Cultural Competence in the workplace • Key strategies to build a culturally competent workforce • Major benefits you stand to gain by having a culturally competent team.

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5S Audit Checklist for Manufacturing Companies by Operational Excellence Consulting

1. © Operational Excellence Consulting. All rights reserved. 5S Audit Checklist for Manufacturing Companies 5S Audit Checklist for the Evaluation of Manufacturing Companies This audit form consists of 25 performance criteria based on the 5S principles for the evaluation of manufacturing companies.

2. © Operational Excellence Consulting. All rights reserved. 2 Contents Summary of 5S Principles 5S Audit Checklist 1 2 NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: http://www.oeconsulting.com.sg

3. Summary of 5S Principles 1

5. © Operational Excellence Consulting. All rights reserved. 5 What is 5S? Principles General Description 1S Sort Remove what is not needed and keep what is needed 2S Set in Order Arrange essential items in order for easy access 3S Shine Keep things clean and tidy; no trash or dirt in the workplace 4S Standardize Establish standards and guidelines to maintain a clean workplace 5S Sustain Make 5S a habit and teach others to adhere to established standards

6. 5S Audit Checklist 2

7. © Operational Excellence Consulting. All rights reserved. 7 5S Audit Scoring 0 4321 We constantly deviate Flawless, no deviations ever For each audit or evaluation criteria in the next five slides, assign a score from 0 to 4: There are a total of 25 questions. You may change the questions to suit your workplace environment. The maximum possible score is 100.

8. © Operational Excellence Consulting. All rights reserved. 8 5S Audit Checklist 1S: SORT Score 1 Unneeded equipment, tools, furniture, etc. are present. 0 1 2 3 4 2 Unneeded items are on walls, notice boards, etc. 0 1 2 3 4 3 Items are present in walkways, stairways, corners, fire exits etc. 0 1 2 3 4 4 Unneeded inventory, supplies, parts, or materials are present. 0 1 2 3 4 5 Safety hazards (water, oil, chemical, machines) exist. 0 1 2 3 4 Sum 1st S:

9. © Operational Excellence Consulting. All rights reserved. 9 5S Audit Checklist 3S: SHINE Score 11 Floors, walls stairs, and surfaces are free of dirt, oil, and grease. 0 1 2 3 4 12 Equipment is not kept clean and free of dirt, oil, and grease. 0 1 2 3 4 13 Cleaning materials are not easily accessible. 0 1 2 3 4 14 Lines, labels, signs, etc. are not clean and unbroken. 0 1 2 3 4 15 Other cleaning problems of any kind are present. 0 1 2 3 4 Sum 3rd S:

10. © Operational Excellence Consulting. All rights reserved. 10 5S Audit Checklist 5S: SUSTAIN Score 21 How many workers understand the 5S principles. 0 1 2 3 4 22 How many times last week was daily 5S not performed. 0 1 2 3 4 23 Number of times that personal belongings are not neatly stored. 0 1 2 3 4 24 Number of times job aids are not available or up to date. 0 1 2 3 4 25 Number of times last week daily 5S inspection were not performed. 0 1 2 3 4 Sum 5th S: Sum of all S’s:

11. © Operational Excellence Consulting. All rights reserved. 11 Score Meter Example 720 85 Area: Machining Department 5S Rating : Excellent Last Updated : Dec 22th, 2016 Comments: Keep up the good work! Very Poor Poor Fair Good Excellent 1 20 40 60 80 100

13. © Operational Excellence Consulting. All rights reserved. 13 5S Monthly Trend Performance 0 10 20 30 40 50 60 70 80 90 100 Jan-16 Feb Apr May Jun Jul Aug Sep Oct Dec 2016 Monthly Audit Results Score Goal

16. © Operational Excellence Consulting. All rights reserved. 16 About Operational Excellence Consulting • Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. • The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions. • OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg

5S Audit Checklist for Manufacturing Companies by Operational Excellence Consulting

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