Production 5S Checklist

Score
Condition Observed
0
Very Good (perfect condition)
Good (1-2 problems)
OK (3-4 problems)
Bad (5-6 problems)
Very Bad (above 7 problems),

or non existant
Score (check box)

1
2
3
Date :_____________________________
Number
Category
Sort(Organization) Distinguish
between what is needed and
not needed
Score
0
Equipments-Health & Safety?
Whether Fire extinguishers,

fire exits clear, PPE, Smoke
detector , Hose pipes, Sand
bag, Eye wash stations and
first aid equipment are
available in the floor
Facilities
Are facility items in the area

broken, damaged
Floors & Gangways
Free of obstructions, fire exits

clear
Visual Control System / Visual Mgt
All information is current and

necessary ?
Storage(trims Accessories , sessior

& Trimmer )
No material storage areas are

overflowing
Awareness Building
all information related to

awareness building are current
& Necessary?
Workbenches & surfaces
No un-necessary items on
workbenches or work surfaces
Wires , Cabiling & Hoses
Are all Wires, Cabling & Hoses

item(Electrical panel board,
Bus bar, Hoses) are current &
Necessary?
Machine Guards, Windows &

Interlocks
All interlocks are operational
10
Duty Technician
11
Emergency
12
Work Place Distribution
13
Sharp Tools
14
Tooling, Fixtures, Jigs
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
No Tools, fixtures & jigs on

workstations unless in use
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
check box)
4
PRODUCTION 5S CH
core
4
Au
dite
d
By
:__
___
___
___
Set in Order (Orderliness) A place ___
for everything and everything in its ___
place
___
___
0
__
Shine(Cleanliness)Cleaning and
looking for ways to keep it clean
and organized
Score
1
All fire extinguishers are charged,

eye wash stations labelled, Smoke
detector Hose pipe and first aid
equipment available and labelled
Are safety glasses & Hose Pipes

clean and in good condition
Have items in the area been

identified that are broken or
damaged ?
The area has floors swept,

machinery clean and generally
clean
Floor Marked per plant standard
Clean (No Dirst, No Spills, No Oil)
Floor visual tracking board layout

constant with plant standard
All postings are neat & orderly in

appearance
All material storage areas are clearly

designated and labeled
Material storage areas only contain

WIP and/or pre-kitted items
All information are available

according to their placement
All Information is orderly place able

and Organize
Workbenches and work surfaces are

organized
Workbenches and work surfaces

are clean and in good condition
Are all Wires, Cabling & Hoses item

(Electrical panel board, Bus bar,
Hoses) are in Quarantine area
Guards and shields in place where
required
All machine windows are cleaned

regularly to area standard
Point of use Items have designated

and clearly organized storage
location
No tooling (measuring equipment,

torque wrenches, pressure gauges)
in area out of calibration
5S CHECKSHEET
Standardize (Adherence)
Maintain and monitor the first
three categories
Score
0
4
Area plan identifies eye wash
stations, fire extinguishers, and
fire exits
Has maintenance request been

raised ?
Floor marking standard created

and posted in the area
Area standard exists and is
posted to define layout and
format
Area plan identifies location of
material storage
All information are monitored

according to SOP
Does a standard exist in the area
that describes what the
workbenches and surfaces
should require
Are
a
Aud
ited
:
___
___
___
___
___
___
___
0
___
_
Score
1
Machine guards, interlocks have

planned maintenance standard
and schedule
Area plan identifies location of

tooling, fixtures & jigs
Sustain (Self-discipline) Make

habit of obedience to the rules
Score
0
Are PPE and safety standards

being adhered to by all
employees in the area
Does an area have a planned

maintenance schedule for all
facilities issues ?
Daily checksheet in place with
sign off & date with improvement
action items
Are all visual tracking board
standards adhered to at all
times ?
Items are returned to designated
area when not in use
Are all workbenches & surfaces

standards adhered to at all
times ?
Machine guards, interlocks are

maintained to planned
maintenance standard
Are all tooling standards adhered

to at all times ?
Standarization - Check
SI- No
1 Keep trolley are in correct place
2 Keep Machice in Right Angle
3 Keep machine cables in Proper hanging position
4 Keep Trimmers Hook To sewing Machine
Keep Work Place Area Clean (Machine, Helpers
5
table
iron Table, Under
machine)
Keep ,Accessories
cup boar
clean & keep
6
materials in allocated space
7 Keep Passage Free
8 Keep Trolley Clean
keep cutting loading trolley clean & Pieces to be
9
in
proper
place
Isolate
The
old style materials & keep in
10
respective area
11 Keep Production Document In Proper place
12 keep Clean the operation waste tag
Keep Operators Launch bags In Respective racks
13
& Clean
In QC table
14 keep
Keep Necessary
Proper InfoInformation
like Style sample
pieces , OB
15 layout , Trims card, Critical Operations Moke up &
integrityWater
in Display
Keep Drinking
Tank Clean
16 Bundle
17 Keep Floor & Window & Cabins Clean
18 Keep Toilet Clean
TWICE PER DAY
0-Bad, 1-Ok, 2- Good, 3-very

4th pillar- stan
CONTINOUSLY
SHINE
5S JOBS
1st 3 pillar
SET IN ORDER
Team: T-13
SORT
Zone: Sewing
Standarization - Checklist
Month
Operators/ Feeding helper/ IE

M/c/ Operators / IE
Electrician/ Machine/ IE
Operators
Operators/ Supervisor
Feeding Helper/ Supervisor/ IE
Supervisor/ IE
Feeding helper / Supervisor
Feeding helper
Operators
Operators
QC
IE/ Supervisors/ QC
House Keeping
House Keeping
House Keeping
TTL
3RD WEEK
2ND WEEK
POINTS
1ST WEEK
RESPONSIBLE
ONCE PER ORDER
ONCE PER MONTH
ONCE PER WEEK
ONCE PER TWO DAYS
ONCE PER DAY
ad, 1-Ok, 2- Good, 3-very Good

4th pillar- standardize
5TH WEEK
4TH WEEK
POINTS
Record Sheet
Zone
Leader
Ref
Code
Date
Inventory Item
Member
Item
Requirement
Physical Area
Needed
Necessity
Red tag
Necessity
Un needed
Visual Requirements For Seiton

Organize flow & connect Workers
Champion
Team Leaders
Start
Due
Factory:
Visuals/3s for the Floor Team
Design poka-yoke (Mistake Proffing) To Ensure That Workers follow 3s
1
2
3
4
5
6
7
a
b
c
d
e
f
g
8
a
b
c
d
e
9
10
11
12
13
14
15
16
17
18
19
20
21
Visual Requirements For Seiton

Organize flow & connect Workers
Visuals/3s for the Floor Team

Design poka-yoke (Mistake Proffing) To Ensure That Workers follow 3s
All tables must be at same sight
All Trimmers/ Scissors / Pencils Must be attached To the machine
Design an area to post the necessary instruction on machines the same way
Allocating a place for the side tables (painted)
Marking the kanban level on the side table (Minimum & Maximum)
Implement Pipeline Table for feeding parts at same frequency
Modular have to have a designated place & visually identified to;
Keep the folders
Keep tools such as (screw drivers, extra foots etc)
Keep input (Name what will be there)
Keep packed cartons
Keep empty cartons
Keep maintenance log book
Keep the key drivers visually
At each work station
Planning the point-of-use boards with simbala instructions needed for each work station
Organize the machine lockers (A place to keep the extra Bobbin ect)
A place to keep thing needed for clean up activities
A place to keep a scrap materials to adjust the machine
A place to put the size tag
Display Decesion making support cadre allocated for the floor
Display the leaders role / members role in local language (Convert into a pledge)
Display the lean objectives with regard to the new floor
Display Picture of the team
A list of all colors used unside the floor (Legend for size colors, other indications used)
Floor name board and picture , style, buyer, and number of weeks style is in process
2 Bulbs for Break-down and input kanban indentiofication (Make sure you name it)
Machine should have a identification no related to TPM
A bin for putting rejects at the end line and a place allocated for keeping it ( Separate the bin for 5 types of rejects )
Audit can use Visual controls for indicating the pass/fail
Allocate a parking area for the trolley
Display 'Meters'
Cover- Up Wires / Nuts etc
Keep Yarn & fabric in correct place

Keep fabric according to style & Dia wise
Keep machine cables in Proper hanging position
Keep Secissors in hanging Position
5 table , Uner Table, Under machine)
Keep machine , Globes & Clips in Allocated Space

6
7 Keep Passage Free
8 Keep Table clean
keep cutting loading trolley clean & Bundle to be in
Proper place
Isolate The old style Fabric & keep in respective
9 area
Keep Workers Launch bags In Respective racks &
12 Clean
13 keep Necessary Information In QC table
Keep Proper Info like Style , fabric quality fabric
14 Composition & quality Check Description
15 Keep Drinking Water Tank Clean
ONCE PER ORDER
ONCE PER MONTH
ONCE PER WEEK
ONCE PER DAY
TWICE PER DAY
CONTINUESLY
ONCE PER TWO DAYS
SI- No
1
2
3
4
SHINE
5S JOBS
0-Bad, 1-Ok, 2- Good, 3-very Good

1st 3 pillar
SET IN ORDER
Team: T-13
SORT
Zone: Sewing
5TH WEEK
4TH WEEK
3RD WEEK
2ND WEEK
1ST WEEK
RESPONSIBLE
klist
Month
POINTS
Keep fabric in correct place

Keep fabric according to style wise

6
7 Keep Passage Free
8 Keep Table clean
Proper place
9 area
12 Clean
ONCE PER ORDER
ONCE PER MONTH
ONCE PER WEEK
ONCE PER DAY
TWICE PER DAY
CONTINUESLY
ONCE PER TWO DAYS
SI- No
1
2
3
4
SHINE
5S JOBS

1st 3 pillar
SET IN ORDER
Team: T-13
SORT
Zone: Sewing
cklist
Month

M/c/ Operators / IE
Operators
Supervisor/ IE
Feeding helper
Operators
Operators
QC
IE/ Supervisors/ QC
House Keeping
House Keeping
House Keeping
TTL
5TH WEEK
4TH WEEK
3RD WEEK
2ND WEEK
1ST WEEK
RESPONSIBLE
POINTS
Keep Yarn & fabric in correct place

Keep fabric according to style & Dia wise

6
7 Keep Passage Free
8 Keep Table clean
Proper place
9 area
12 Clean
ONCE PER ORDER
ONCE PER MONTH
ONCE PER WEEK
ONCE PER DAY
TWICE PER DAY
CONTINUESLY
ONCE PER TWO DAYS
SI- No
1
2
3
4
SHINE
5S JOBS

1st 3 pillar
SET IN ORDER
Team: T-13
SORT
Zone: Sewing
klist
Month

M/c/ Operators / IE
Operators
Supervisor/ IE
Feeding helper
Operators
Operators
QC
IE/ Supervisors/ QC
House Keeping
House Keeping
House Keeping
TTL
5TH WEEK
4TH WEEK
3RD WEEK
2ND WEEK
1ST WEEK
RESPONSIBLE
POINTS
Zone: Sewing
Team: T-13
5S JOBS
SI- No
1 Lockers
No irrelevant reference materials, such as documents, drawings, meeting materia
2 Desk
No excess pieces of equipment or reference materials on desk or in
3 Visual Control
rrelevan items or documents can be identified at a glance.
4 Standards for Disposal
Standards are fixed for disposal of documents and equipment.
5 Exhibits
Displays are up-to-date, tidy, and well-balanced.
6 Storage labels
Labeling of lockers and equipment allows immediate identification.
7 Labels for documents and eq Everything is clearly identified.

8 Ease of use
Storage is designed for ease of use.
9 Orderly storage
Everything is stored in a fixed place.
10 Aisles and display areas
All dividing lines and bulletin boards are clearly indicated
11 Floor
The floor is clean
12 Dust and Dirt
Windows, window sills and shelves are clean
13 Cleaning responsibilities
There is a rotation or shift system for cleaning
14 Wastebaskets
There is a system for getting rid of dirt and waste paper
15 Habitual cleaning
Sweeping and dusting are regarded as habitual activities
16 Ventilation
The air is clean, odorless, and free of cigarette smoke
17 Lighting
The angle and intensity of illumination are appropriate.
18 Uniforms
No body is wearing a dirty uniform.
19 Environment
The general environment is good, including color, air, lighting, etc.
20 The first 3 steps
There is a system for maintaing clearing up, organizing, and cleaning.
21 Clothing rules
The rules are adhered to.
22 Interaction of people
There is a pleasant general atmoshere, people exchange greetings, etc.
23 Meeting times and break timeEveryone makes an effort to be punctual.

24 Telephone Manners
Everyone states their business clearly, politely, and succinctly.
25 Rules and Regulations
All rules and regulations are strictly observed.
wings, meeting materials, etc.
nd cleaning.
eetings, etc.
5TH WEEK
4TH WEEK
3RD WEEK
1st 3 pillar 4th pillar- standardize

2ND WEEK
1ST WEEK
RESPONSIBLE
SORT
SET IN ORDER
SHINE
CONTINUESLY
TWICE PER DAY
ONCE PER DAY
ONCE PER TWO
DAYS
ONCE
PER
WEEK
ONCE
PER
MONTH
ONCE PER
ORDER
arization - Checklist
Month
POINTS
Ref
Item name Mnf No
Red tag Evaluation Sheet

Red tag Item Movement
When
To where Which Purpose How many By Whom

Production 5S Checklist

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Score

Very Good (perfect condition)

Good (1-2 problems)

Bad (5-6 problems)

Very Bad (above 7 problems),

Score (check box)

Equipments-Health & Safety?

Whether Fire extinguishers,

Are facility items in the area

Floors & Gangways

Free of obstructions, fire exits

Visual Control System / Visual Mgt

All information is current and

Storage(trims Accessories , sessior

No material storage areas are

all information related to

Workbenches & surfaces

Wires , Cabiling & Hoses

Are all Wires, Cabling & Hoses

Machine Guards, Windows &

All interlocks are operational

Work Place Distribution

Tooling, Fixtures, Jigs

No Tools, fixtures & jigs on

All fire extinguishers are charged,

Are safety glasses & Hose Pipes

Have items in the area been

The area has floors swept,

Floor Marked per plant standard

Clean (No Dirst, No Spills, No Oil)

Floor visual tracking board layout

All postings are neat & orderly in

All material storage areas are clearly

Material storage areas only contain

All information are available

All Information is orderly place able

Workbenches and work surfaces are

Workbenches and work surfaces

Are all Wires, Cabling & Hoses item

All machine windows are cleaned

Point of use Items have designated

No tooling (measuring equipment,

Has maintenance request been

Floor marking standard created

All information are monitored

Machine guards, interlocks have

Area plan identifies location of

Sustain (Self-discipline) Make

Are PPE and safety standards

Does an area have a planned

Are all workbenches & surfaces

Machine guards, interlocks are

Are all tooling standards adhered

TWICE PER DAY

0-Bad, 1-Ok, 2- Good, 3-very

Operators/ Feeding helper/ IE

ONCE PER ORDER

ONCE PER MONTH

ONCE PER WEEK

ONCE PER TWO DAYS

ONCE PER DAY

ad, 1-Ok, 2- Good, 3-very Good

Visual Requirements For Seiton