BALCO Limited

5S Audit Check List

Doc.No:BALCO/ENABLING/BE/IMS/AO/Doc 003
Auditor

Auditor

Rev.No-00

Ver.No-00

Date-07.04.2014

Audit Zone :

Audit Date

5S Audit Check List - Scoring Guidelines

5S - ShitsukeSustain (Discipline)

4S - SeiketsuStandardise

3S - Seiso- Spic & Span 2S - Seiton -Set in order

1S - Seiri -Sorting

S.No

Check Item

Evaluation Status / Criteria

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.

Tools, Accessories, Fixtures

etc.

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.

Shelves, Lockers and

all Items in Storage

Cleaning of Almirah, shelves, lockers and other storage places in place.

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.

Walls, Roofs, windows

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

Clean and sparkling toilets, no bird droppings , no pest found in shops/workplace

Over Flows, Leakages

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

Awareness & Training

Every body in department is trained in 5S awareness,SOP's and safety methods and retrained
whenever required.

Compliance to Standards &

safety instructions

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

No stagnancy in 5S scores; Improvement projects identified to remove unsafe

conditions,fatigue reduction, cycle time reduction thro muda elimnation

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

3S - Seiso- Spic & Span 2S - Seiton -Set in order

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

Every where dirt and every thing is dusty

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

No systematic training/adherence to standards (PPE , SOP etc)

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