5S Audit Checklist - Shopfloor

5S AUDIT CHECKLIST FOR SHOPFLOOR DEPT:______________________________________

IED-GE-OC-FO-102 Rev.0 DATE:_________________________________

AREA/SECTION:______________________________________ WORKPLACE STANDARDS STANDARDS PRODUCTION AREA - ENTRANCE (Note: Applicable for food facilities) With hand washing area, properly equipped with soap and hand dryer. 1 2 3 4 5 6 7 8 9 10

With footbath sufficient with width, length and height to disinfect lower half of boots. Are free from insects and pests. Area free from insects and pests. With proper signages. RACKS/ OPEN SHELVES Are free from dust, stains, cobwebs, spillage, rust and are well-maintained. Are labeled properly. Items stored inside drawers are properly arranged. Items stored match the identification of label. No food and personal items stored.

21 22

CABINETS / TOOL BOX Are free from dust, stains, cobwebs, spillage, rust and are well-maintained. Are labeled properly. Items stored are properly arranged. Items stored match the identification of label. No food and personal items stored. Closed at all times when not in use. Tools and small instruments are cleaned and returned to designated storage after use. No defective tools and small instruments. WORKING TABLES Are free from cobwebs, rust and are well maintained. Are free from dust, stains and spillage after any activity. Items on top of tables are kept clean and properly arranged and stacked when not in use. CONTROL PANELS Are free from dust, stains, cobwebs, drippings, rust and are well-maintained. Are properly labeled.

23 24

CONTROL PANELS No items stored inside except for control panel manuals. Panel doors are closed at all times except during maintenance and inspection.

11 12 13 14 15 16 17

18 19 20

25 26 27 28 29 30 31 32 33

SEATING UNITS Are kept clean and in good condition at all times. Nothing is placed on top of chairs PARTITIONS Are free from rust, cobwebs and well-maintained. Nothing hanged on it except signage. WINDOWS / DOORS / GATES Are free from dust, stains, cobwebs, rust and posted materials. Are in good condition at all times (including venetian blinds and curtains). Doors and gates are free from obstructions. Two-way doors are provided with directional signs. Windows and doors provided with screen to prevent entry of flies and other insects. (Note: For food facilities)

38 39

WINDOWS / DOORS / GATES Doors are wide enough to ensure no contact between door jambs and means of conveyance. (Note: For food facilities) Doors are self-closing. (Note: For food facilities) Doors are non-permeable. (Note: For food facilities) Doors fit perfectly when closed. (Note: For food facilities) FLOORS Are free from litter, stains and drippings after any activity. Are free from protrusions, nails, unsecured wires, cords and other obstructions.

40 41 42 43 44 45

Are free of slip, trip or fall hazards. Safety markings are visible at all times. No missing or damaged tiles. No peeled off epoxy paint. No missing canal covers/strainers. No clogged drains and stagnant water. Easy to clean. (Note: For food facilities)

34 35 36 37

46 47 48 49

FLOORS Made up of non-slippery ceramic tiles, cement or synthetic materials. (Note: For food facilities) Free of cracks and indentation. (Note: For food facilities) Junction with wall is rounded. (Note: For food facilities) WALLS Are free from stains and cobwebs.

CONFORMS ? YES (/) NO (X)

REMARKS/STATUS



AREA/SECTION:______________________________________ WORKPLACE STANDARDS Are free from memos, notes and notices. No big cracks or holes. No graffiti. Only the following can be hanged/nailed on walls: o work-related/decorative framed materials o directional and instructional stickers/signs o business and other permits o religious items Note: Any new item that will be hanged/nailed on walls are to be referred first to Admin. Services for approval. Are non-permeable. (Note: For food facilities) 54 Are easy to clean. (Note: For food facilities) 55 50 51 52 53

56 57 58 59 60 61 62 63 64 65 66

67 68 69 70 71 72 73 74 75 76 77 78

79 80 81 82 83 84 85 86 87 88 89 90

91 92 93 94 95 96 97 98 99 100 101 102

WALLS Are free of cracks and crevices. (Note: For food facilities) With rounded corners. (Note: For food facilities) CEILINGS Ceilings, roof, insulation, light diffusers and air ducts are free from dirt, stains and cobwebs. No roof leaks and flaking of paint. No missing or peeled off boards. No damaged insulation. No cracked or missing light diffusers. No busted light bulb. AISLEWAYS AND PASSAGEWAYS Are clear and unobstructed. At least 28 inches wide. Permanent aisles and passageways clearly marked. Covers and/or guardrails provided when aisled or passageways are near open pits, tanks, vats, ditches or similar hazards. PLATFORMS / SCAFFOLDING Working platforms at least 24 inches wide. '4-inch toeboard provided along all sides. Non-skid flooring provided. Access gates self-closing and locking. Equipped with standard guard rail if over 10 feet above floor. Sound, rigid footing for scaffolds. No accumulation of tools or materials. No altering or moving of scaffolds in use. STAIRWAYS At least 22 inches wide. Steps uniform in height and tread depth. Are free from litter, dust, stains, cobwebs, rust and spillage. Are free from unsecured wires, cords, obstructions and tripping hazards. STAIRWAYS Stairs having 4 or more risers are provided with standard hand rails on open sides. Open risers if less than 9-inch tread depth. No damaged stairway risers and handrails. Surface slip resistant. Long flights broken by platforms. Outdoor stairs have grating type treads. EXITS/EGRESS Sufficient exits for prompt escape (at least 2 exits from one area). Exit doors not locked. Routes and exits clearly marked. Exits adequately illuminated. Approaches to exits ubobstructed. Flammables kept out of exits. EXITS/EGRESS At least 28 inches wide. Open outward onto level floor. ROADWAYS Surfaces in good condition. Sufficient width and vertical clearance provided. Standard signs and marks present. Rail sidings in good condition. VENTILATION Adequate means provided. Air inlets and openings arranged to minimize escape of contaminants. Enclosures provide continuous inward air flow. Separators provided if air is recirculated. Hoods draw air away from people and connected to exhaust system. Ductwork made of non-combustible material, sealed and adequately supported,


REMARKS/STATUS



AREA/SECTION:______________________________________ WORKPLACE STANDARDS

105

VENTILATION Ventilation facilitates removal of objectionable odor, heat and moisture and entry of clean fresh air. (Note: For food facilities) NOISE EXPOSURE Protection provided when sound levels exceed standard. LIGHTING Walking and working areas adequately illuminated during periods of occupancy.

106 107

Lighting fixtures clean. Illumination level sufficient for detail of work performed; no shadowing or glare.

108 109

Lighting properly covered with non-glass material. (Note: For food facilities) Emergency lighting of all exit routes not naturally lighted. STACKING AND STORAGE Aisleways and access paths clear and unobstructed. Small or irregular shaped items properly blocked, interlinked, with proper limitations in heigt of storage. All stacks stable and secure against sliding/collapsing. Proper drainage in storage area. Storage area clean and cleared of foreign objects/materials.

103

104

110 111 112 113 114

115 116 117 118 119 120 121 122 123 124 125 126 127

STACKING AND STORAGE Racks and platform load limits posted and observed. With sufficient pallets, shelves and racks to hold usual inventory. (Note: For food facilities) Raw materials are stored according to prescribed storage condition. (Note: For food facilities) Proper separation of food and non-food items. (Note: For food facilities) Stored materials are properly tagged with identification, delivery and expiry date. (Note: Applicable to food facilities) Follows FIRST IN, FIRST OUT system in issuing raw materials and finished goods. (Note: For food facilities) Separate storage area for raw materials and finished goods. (Note: For food facilities) Proper ventilation system. (Note: For food facilities) Provision of pest and insect control. (Note: For food facilities) Area facilitates smooth traffic for the reception and release of materials. (Note: For food facilities) No condensation. (Note: For food facilities) MATERIALS HANDLING Containers in good condition. Pallets and skids of correct type and in good condition.

132 133 134 135 136 137 138 139

MATERIALS HANDLING Materials on pallets are properly piled. Chains, slings and ropes adequate for loads and in good condition. Lifting equipment properly stored. CHEMICALS AND FUELS Tanks/drums made of steel or appropriate material, adequately supported, grounded and bonded. Limited to 2,500 gallons if above ground. Tanks adequately venred and provided with pressure relief valves. Adequate spill containment. Proper spill absorbent materials provided. Container corrosion prevention provided. Temperature controlled to prevent boiling. Adequate storage cabinets provided; fire resistant and vented. Storage heated by means not constituting a source of ignition.

140 141 142 143 144 145

COMPRESSED GASES Stored upright and secured against falling over. Segregated by contents and legibly marked. Caps in place and hand tight. Protected against rust/corrosion. Stored away from heat sources. Stored away from stairs, elevators, and egress routes.

128 129 130 131


REMARKS/STATUS



AREA/SECTION:______________________________________ WORKPLACE STANDARDS

146 147 148 149 150 151 152

153 154 155 156 157 158 159 160 161 162 163 164

165 166 167 168 169 170 171 172 173 174 175

HAND AND PORTABLE TOOLS Tools, electrical cords and air hoses in proper general condition. Stored properly when not in use. Guards and safety devices serviceable. Electrical grounding or double insulation serviceable. Power tools equipped with constant pressure switches. Tool retainers installed on pneumatic tools. Adjustment correct. HAND AND PORTABLE TOOLS Load rating sufficient for work performed. MACHINE TOOLS AND GUARDING Mechanical power transmission guarded. Pinch points, in-running nip points, and points of operation guarded. Fixed guards secured in position. Interlock guards operative. Automatic guards properly adjusted. Operating controls guarded against inadvertent actuation, locked and key removed when not in use. Emergency stop buttons operational, correctly positioned, labeled, and color coded. Isolation and lock-out provided for servicing. Guards provided for rotating parts, chips or particles, sparks, kickbacks, etc. Operator and service manuals available. CONVEYORS Gears, shafts, pulleys guarded on nip points. CONVEYORS Drop guards installed to catch falling material. Emergency stop controls adequately located and operational. PRESSURE VESSELS Meters and controls located on operating floor. Safety valves operational. Drains clear and freeze protected. Inspection certificate/label appropriate to type. Pipes, connections, vessels free of dents, notches and severe scratches. Shields, platforms and landings as appropriate. VALVES AND MECHANICAL CONTROLS Are color-coded and properly identified with water-proof labels. Operational Readily accessible.

185

PIPELINES Are color-coded for identification of hot and cold water and steam. Pipelines for hot water and steam are properly insulated. Are properly marked and self-draining. SIGNS AND TAGS Hazard warning, directional and informational signs and tags used where there are immediate dangers, potential hazards, or there is a need for general instructions. Signs and tags consistent in use throughout the facility. Tags affixed to all defective equipment not secured against use. COLOR CODING Red color coding used to indicate immediate danger. Yellow color coding used to indicate changing conditions. Orange color coding used to indicate areas under modification, hazardous parts when guards removed. Green color coding used to indicate safety insructions and first aid equipment.

186 187

Blue color coding used for general information signs and tags. Color coding systems used to indicate fluid and gas system contents.

176 177 178 179

180 181 182 183 184

188 189 190 191 192 193 194 195 196 197 198

199 200

MATERIALS LABELING Standard labels affixed to all containers of hazardous substances in storage and use. Standard labels affixed to vehicles transporting hazardous materials. Labels legible and visible. MULTI-PURPOSE TANKS Are free from dust, stains, leaks, cobwebs, rust, unofficial stickers and wellmaintained. Are properly labeled. No items placed on top and beneath. Equipped with level controls to prevent overflow. MACHINERY AND EQUIPMENT Are free from dust, stains, leaks, cobwebs, rust, unofficial stickers, unnecessary drippings of oil or grease and well-maintained. Are properly labeled. No loose spare parts/tools/personal items lying on top, inside and beneath the equipment. Are in good operating condition. MACHINERY AND EQUIPMENT All moving parts are guarded. Machine guards/doors are closed when machine is operating except during trouble shooting.


REMARKS/STATUS



AREA/SECTION:______________________________________ WORKPLACE STANDARDS 201

202 203 204 205 206 207 208 209 210 211 212

213 214 215 216 217 218

219 220 221 222 223 224 225 226 227 228

229 230 231 232 233 234 235 236 237 238 239 240

241

242 243 244 245 246 247 248 249 250


Are installed at a minimum of 12 inches (greater distance for large equipment) from walls, support structure and other stationary structure. (Note: For food facilities) Equipment and instrument location facilitate one-way process flow. (Note: For food facilities) Equipment and instruments/accessories are made up of non-corrosive materials. (Note: Applicable for food facilities) Facilities and equipment do not transmit toxic substances, odor and taste to products. (Note: For food facilities) Under controlled temperature as required by controlling authority. (Note: Applicable for food facilities) No material made of wood and breakable glass. (Note: For food facilities) APPLIANCES Are free from dust, stains, unofficial stickers and well maintained. ELECTRICAL Switches and outlets are clean and operational. No broken switches and outlets. No hanging connections, exposed or faulty wiring. All equipment and appliances must be turned off and set aside after use. Wiring of equipment and appliances are properly laid out. No octopus connections. ELECTRICAL POWER SYSTEMS High voltage and control panels closed and secured. Control panels identified and accessible. Wiring, insulation and fixtuers in good condition. Explosion-proof fixtures provided in dusty or flammable vapor areas. Flexible cords free of splices. WARNING SYSTEMS Fire/Emergency alarm systems operational. WARNING SYSTEMS Hazard warning systems on appropriate vehicles and equipment. Overpressure warning systems on pressure vessels. Overtemperature warning systems on fired pressure vessels, hazardous material storage, powered equipment. Warning signs and devices for railway sidings available. EMERGENCY INSTRUCTIONS Operational placards/decals on emergency controls (on-off, open-close, etc.) Emergency instructions at primary telephone in each work area. Fire Hazard symbols on facilities containing hazardous substances. FIRE PROTECTION Potable extinguishers appropriate to type of materials readily available. Extinguishers inspected monthly. Fire hoses properly mounted and accessible. FIRE PROTECTION Fire equipment visibly marked. Fire doors, lids and shutters in good condition with fusible links intact. Sprinkler heads have minimum clearance from materials and furnishings. Sprinkler master control valves accessible and locked open. Personal protective equipment for fire brigade members in good condition. EYE BATHS AND SHOWERS Readily available and accessible in areas where caustic/corrosive chemicals are used. Water supply provides 15 minute flush at comfortable temperature. Proper signs and instructions. Flushed frequently to eliminate contaminants. FIRST AID KITS / STATIONS / EQUIPMENT Located as prescribed by legislation and organizational medical policy. Adequate materials and equipment available and properly located. Electrical safety items included in high voltage areas. DRESSING ROOM, TOILET AND WASH ROOM Toilet equipped with the following at all times: o toilet paper o liquid soap in soap dispenser/container o trash can o mirror Lavatories, urinals and toilet bowls are sufficient and kept clean. Fixtures are in good working condition. Well ventilated. Entrance doors are closed at all times. No faucet leaks. With adequate water supply at all times. Are free from cigarette butts, ashes and stains. In good state of repair. (Note: For food facilities) With disinfectant and hand dryer. (Note: For food facilities)

REMARKS/STATUS



AREA/SECTION:______________________________________ WORKPLACE STANDARDS 251

Does not directly open to working/processing area. (Note: For food facilities)

252

Adequate dressing rooms with lockers for personnel. (Note: For food facilities)

253

Provision for protective clothing (masks, hairnets, gloves) for plant personnel. (Note: For food facilities) Conspicuously posted instructions for personnel hygiene of plant workers. (Note: For food facilities) MEDICAL FACILITY Presence of clinic for treating minor injuries. With resident nurse or doctor. SEWAGE AND WASTE DISPOSAL SYSTEM Properly constructed drains. With adequate traps and vents, catch basins, sump pits. Drainage line of toilet is not connected with drainage line for plant. All drainage properly covered. No waste accumulation.

254

255 256 257 258 259 260 261

269

CLEANING TOOLS AND CHEMICALS Are maintained in desired temperature condition and kept away from the processing area. (Note: For food facilities) Conveniently located in working stations. (Note: For food facilities) With proper identification. (Note: For food facilities) DRESS CODE Employee ID is worn at all times within the company premises. IDs are not dilapidated and without personal stickers. PPEs (Personal Protective Equipment) are worn at all times. Employees wear complete and clean uniform. Uniform is worn properly. PERSONNEL HYGIENE No wearing of personal accessories like jewelries, etc. (Note: For food facilities)

270 271

No sick workers alllowed to work. Microbiological hand swab test regularly conducted.

262 263 264 265 266 267 268

272 273

274 275

276 277 278 279 280 281 282 283

REMARKS/STATUS

TELEPHONE COURTESY Telephone calls are answered within 3 rings. The person answering the phone identifies himself or herself by saying, "Thank you for calling (name of department)", Good Morning or Good Afternoon" as the case may be. The caller is advised if the call will be transferred to another The person answering the phone takes note of the message, if the person he or she is looking for is not available to take the call and ensures that message is relayed. OTHERS Buildings are properly labeled. Plant location free from objectionable odor, flying ash and dust and not subject to flooding. Surroundings are free from litter (excluding those coming from the plants) and spillage (e.g., oil, grains, powder, etc.) Solid waste is properly segregated. Perimeter fencing to prevent entry of unauthorized persons and animals. Scrap materials are properly piled on pallets and in designated areas. Receiving and dispatching areas separated. No smoking in prohibited areas in support of the Workplace Non-Smoking Policy.

WP CONFORMANCE RATING COMPUTATION A Total Number of Standards B Less: Total Number of Non-Conformances C Total number of Conformances ( C = A - B ) D WP Conformance Rating WP RATING (% of Standards Complied With) 90-100% 75-89% 50-74%


Exceeds Expectation (EE) Meets Expectation (ME) Needs Improvement (NI)

General Remark or Recommendation:

D = (C/A) * 100% Audited By/Date: WP Auditor Conforme/Date: Auditee/Dept Representative Noted By/Date: WP Audit Team Leader

5S Audit Checklist - Shopfloor

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