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Five "S" Routine Checklist Started
Work Area: Performed by:
YES
Sorting
1
Needed and not needed items are identified.
2
Needed and not needed items are identified and those not needed are removed from work area. Initial cleaning has been performed and sources of spills and messes are identified and corrected. Work area has agreements on housekeeping responsibilities and schedules, and alignments are consistently followed. Cleanliness problems areas are identified and mess prevention actions are in place.
3 4 5
Set-in-order
1 2 3 4 5
Simplifying has begun but items are placed randomly throughout the workplace. Needed items are safely stored and organized according to frequency of use. Needed items are outlined, dedicated locations are properly labeled, and required quantities are determined. Needed items in work area have been minimized in number and are properly arranged for retrieval and use. Needed items can be retrieved within 30 seconds and require minimal number of steps.
Shine
1
Work areas to be checked have been identified.
2
Work areas to be checked are identified and acceptable performance levels documented and posted. Visual controls and indicators are established and marked for the work area equipment, files, and supplies. Inspection occurs during daily cleaning of work areas and equipment and supplies are restocked. Potential problems are identified and countermeasures are documented.
3 4 5
Standardize
1
Work area methods are developed and documented.
2
Work group documented agreements for needed items, organization, and work area controls. Work group has documented agreements and visual controls, labeling of items, and required quantities of needed items. Reliable methods and standards for housekeeping, daily inspections, and workplace arrangements are documented and followed by work group. Reliable methods and standards for housekeeping, daily inspections, and workplace arrangements are shared and are used throughout similar work areas.
3 4 5
Sustain
1 2 3 4 5
Date:
Work area checks are randomly performed and there is visual measurement of 5S performance. Initial 5S level has been determined, and performance is documented and posted in work area. Work group is routinely checking area to maintain 5S agreements. Sources and frequency of problems are documented as part of routine work, root causes are identified and corrective action plans developed. Root causes are eliminated and improvement actions focus on developing preventative methods.
NO
Completed YES
NO
Comments
Comment Section Sorting
1 2 3 4 5 Set-in-order
1 2 3 4 5 Shine
1 2 3 4 5 Standardize
1 2 3 4 5 Sustain
1 2 3 4 5
Five S Office Visual Checklist - # 1 Goal: to establish the following three items: 1. To have a place for everything (supplies, office equipment, furniture, and most importantly, information) 2. To have everything in its place 3. To have a way to locate anything we might need to do our jobs (provide a service)
Date:
Area:
Team:
Can each item below be answered visually? Fill in any additional items you might see,
Yes
1. Area and/or Room a. Does the area and/or room have a manifest? b. Does the manifest include the location and description of furniture? c. Does the manifest include the location and general description of information? d. Does the manifest include the location of supplies and equipment and their general descriptions? e. Does the manifest include the locations and descriptions of the people who work in the area? f. Is there an emergency exit manifest and procedure posted? g. Are fire exits clearly visible? h. I. j. 2. Hard Copy Information (notebooks, folders, lists, reports, memoranda, etc.) a. Can the information be located in 30 seconds or less by everyone? b. Are the locations labeled? c. Have locations for moveable equipment been outlined with tape (book case, filing cabinet)? d. Does the storage location or device include a log or table of contents? e. Does the log or table of contents also indicate how to use the information? f. Does the log or table of contents also include primary and secondary contact names and phone numbers? g. Has the information been properly labeled? What is it? When was it created? Where is it stored? How many pages does it have? How many copies exist? Is it a controlled document? h. Is the information easily located within the storage device (color coding and labels)? I. Do we know how long we must store the information or how long until it has expired? j. k.
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No
Five S Office Visual Checklist - # 2 Goal: to establish the following three items: 1. To have a place for everything (supplies, office equipment, furniture, and most importantly, information) 2. To have everything in its place 3. To have a way to locate anything we might need to do our jobs (provide a service)
Date:
Area:
Team:
Can each item below be answered visually? Fill in any additional items you might see,
Yes No
3. Electronically Retrievable Information a. Can the information be located in 30 seconds or less by anyone (okay, one minute for a slow computer)? b. Is there a hard copy location log for the electronically retrievable information in the area? c. Have the hard copy log locations been labeled? d. Does the log contain storage method (e.g., email, hard drive location, disk, tape, mainframe, etc.)? e. Have locations for moveable equipment been outlined with tape (book case, filing cabinet)? f. Does the storage location or device include a log or table of contents? g. Does the log or table of contents indicate how to use the information? h. Does the log or table of contents include primary and secondary contact names and phone numbers? I. Has the log information been properly labeled? What is it? How was it created (operating system, software application, and version)? Who created it? Where is it stored? How many pages does it have? How many copies exist? Is it a controllable document? j. Is the information easily located within the storage device? k Do we know how long we must store the information or how long until it has expired? l m 4. Office Equipment and Supplies a. Have locations for mobile items been outlined with tape? b. Is the home address on each border? c. Is each item labeled? d. Do the address and label show the count or quantity (e.g., 1 of 4)? e. Have minimum and maximum levels been added to the home address? f. Are these items included on the area/room manifest? g. Are the specifications and/or restock numbers on the labels? h. Are the name and phone number of the supplier or service organization included on the address or label? I. Is the disposal method included on the address or label? j
Are hazardous areas on equipment properly identified?
k. Are service records posted? 14826304.xls Office Visual Checklist__2
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l.
14826304.xls Office Visual Checklist__2
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Five S Office Visual Checklist - # 3 Goal: to establish the following three items: 1. To have a place for everything (supplies, office equipment, furniture, and most importantly, information) 2. To have everything in its place 3. To have a way to locate anything we might need to do our jobs (provide a service)
Date:
Area:
Team:
Can each item below be answered visually? Fill in any additional items you might see,
Yes No
5. People a. Does each workstation include the following information: Individual? Phone Number? Picture? Alternate's name? In or out status? Job responsibility or service provided? Is a skill matrix posted at the work station? b. Is the individual's part of the room or area manifested? c. d.
14826304.xls Office Visual Checklist__3
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TAG Work Area:
Tag No:
Category: 1. Raw material 2. Work in Progress 3. Finished Material 4. Tools 5. Supplies
6. Equipment 7. Furniture 8. Office material 9. Books/magazines 10. Other
Item Description:
Five S Tag Form Quantity:
Date:
Reason Tagged:
Suggested Action: 1. Discard 2. Storage 3. Long-term storage
4. Reduce inventory 5. Sell/transfer 6. Other (specify)
14826304.xls Red Tag
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Five S Surplus Items Form Item Name
Action to Take
14826304.xls Surplus Items
Date
Owner
02/18/2009 08:47:14
14826304.xls Surplus Items
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Five S Routine Checklist Date Work Area:
Performed by: 5 S Level
5S No.
Description
1 2 3 4 5
Comments
1 Do all employees know why the 5S program is in place? 2 Have criteria been established to distinguish necessary from unnecessary?
Sort
3 Has a reliable method been developed to prevent unnecessary items from accumulating? 4 Is there any broken, unused or unnecessary equipment or items located in the area? 5 Are there any unresolved Red Tagged items still located in area? 6 Is shelving, racking and cabinets used for storing / hiding junk? 7 Is the area generally overcrowded? Rating 1 Are there maximum and minimum indicators for equipment and supplies? 2 Are aisles clearly marked and free from obstruction?
Set In Order
3 Are equipment and supplies returned to their designated location? 4 Is there a visually marked, specified place for everything? 5 Is storage well organized, clearly labeled and items easily retrievable? 6 Are items like tools and supplies conveniently located? 7 Are visual aids in use (color coding, signboards, outlining)? 8 Does all mobile equipment have a clearly identified storage location (outlining)? 9 Are there specific areas marked for WIP, Finished Products, Nonconforming product? 10 Are there specific areas for order, inspection or in-process paperwork? Rating 1 Is the work area floor well swept and clean from debris? 2 Are cleaning checklists established for the area?
Shine
3 Are the machines / tools in the work area kept clean and in proper working condition? 4 Is there oil, grease or dust on the floors and machines? 5 Is trash removed in a timely manner (are trash cans currently filled or overflowing) ? 6 Are cleaning materials (brooms, dust pans, cleaning fluids) easily accessible? 7 Are manuals, labels and tags in good condition? 8 Would you feel comfortable giving our top customer a tour through this area? Rating 14826304.xls Audit Check List
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1 Are current processes documented (flow charts, process guidelines, procedures)? 2 Do employees have access to information they require?
Standardization
3 Is there a method in place to remove outdated material? 4 Do all employees understand the processes that pertain to them and are they consistent? Does a system exist that provides employees the opportunity to improve existing
5 processes?
Are there multiple tools being used that could be replaced by one all-encompassing tool
6 or tool cart?
7 Have rules and procedures been established to maintain the 1st three 5 S's? Rating 1 2 3
Sustain
4 5 6 7
Are safety and housekeeping policies established and followed? Are there any safety risks evident that are not being addressed? Is safety data, productivity, quality, financial & 5S results posted in the appropriate areas? Are cleaning schedules established, posted and followed? Are equipment PM schedules established, posted and followed? Do employees take ownership of machine / work station cleanliness? Are personal items stored neatly? Are tools and other supplies returned to their proper storage location immediately
8 following their use? 9 10
Are display boards current? Are 5 S routine checks performed regularly? Rating Rating Level
Report Procedure: 1. During each routine check, assess the compliance to the 5 S Level of Achievement for each of the 5 S descriptions. 2. Determine the overall 5 S level for each of the 5 S's. 3. Mark the Level of Achievement on the Progress Form.
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Five S Progress Form Tool
Goal
Actual
Sort
5
4
Set In Order
5
5
Shine
5
4
Standardize
5
4
Sustain
5
4
Sort 5
Set In Order
Sustain
4
Shine
Standardize
Five S Levels of Achievement Level V: Continuously Improve
Level IV: Focus on Reliability
Level III: Make It Visual
Level II: Focus on Basics
Level I: Just Beginning
Check Box for Appropriate Level
Cleanliness problem areas are identified and mess prevention actions are in place.
Needed items can be retrieved in 30 seconds and require a minimum number of steps.
Potential problems are identified and counter measures are documented
Work area has documented housekeeping responsibilities and schedules, and the assignments are consistently followed.
Needed items in work area are minimized in number and are properly arranged for retrieval and use.
Inspection occurs during daily cleaning of work areas and equipment and supplies are restocked.
Initial cleaning has been performed and sources of spills and messes are identified and corrected.
Needed items are outlined, dedicated locations are properly labeled, and required quantities are determined.
Visual controls and indicators are established and marked for the work area, equipment, files, and supplies.
Needed and not-needed items are identified and those not needed are removed from work area.
Needed items are safely stored and organized according to frequency of use.
Needed and not-needed items are mixed throughout the work area.
Items are placed randomly throughout the workplace.
Sorting
Set In Order
Reliable methods and standards for housekeeping, daily inspections, and workspace arrangement are shared and are used throughout similar work areas. Reliable methods and standards for housekeeping, daily inspections, and workplace arrangement are documented and followed by all members of the work group. Work group has documented agreements on visual controls, labeling of items, and required quantities of needed items
Root Causes are eliminated and improvements actions focus on developing preventive methods.
Key work area items to be checked are identified and acceptable performance levels documented.
Work group has documented agreements for needed items, organization, and work area controls.
Initial 5S level has been determined, and performance is documented and posted in work area.
Key work area items checked are not identified and are unmarked.
Work area methods are not consistently followed and are undocumented.
Work area checks are randomly performed and there is no visual measurement of 5S performance.
Shine
14826304.xls Levels of Achievement
Standardizing
Sources and frequency of problems are documented as part of routine work, root causes are identified, and corrective action plans are developed. Work group is routinely checking ara to maintain 5S agreements
Sustaining 02/18/2009 08:47:15
Five S Routine Check Report (1) Date:
(2) Area:
(3) Check Performed by: (4) Improvement Opportunity by:
(5) Countermeasures:
(6) Responsibility:
(7) Target Completion Date:
(8) Actual completion date:
Report Procedure: 1. For each improvement opportunity identified during routine check, fill in this report through section (4). 2. Review all reports with th work group, Identify the necessary countermeasure, assign responsibility, and target a completion date. 3. Review progress against target date; record actual completion date after completion of countermeasure. 14826304.xls Routine Check Report
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