Advance 5S Audits

Improving and Sustaining The Performance Of An

Organization

Prepared by: A. Anthony Charles (BSc.Hons, MSc.TQM, CIPT, CIPTM, CIPTC, CSSBB, CQIC)

INSOL Consultancy Sdn Bhd

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What’s On The Menu

• Module 1: Overview of 5S

• Module 2: Auditing 5S Activities

• Module 3: 5S Audit Cycle

• Module 4: Audit Checklist (Excel Spreadsheet)

• Module 5: Auditing Report and Follow up

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Purpose of This Module

• To develop in-house 5S auditors capable, of undertaking cross-functional 5S Audits.

• Promote objectivity and consistency into the organization’s Audit Process.

• Provide participants with practical experience through case study exercise and “Live” audit.

• To enable participants to utilize internal audits as a tool for management in the continuous improvement process.

• To produce effective audit reports.

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Module 1 – Introduction

Overview of 5S

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What is 5S?

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5S uses the five pillars of 5S and an added pillar for Safety

Improvement system designed to reduce waste and optimize productivity in the workplace. How do we do it?

• Creating and maintaining organization and orderliness

• Using visual cues to achieve more consistent operational results

• Reducing defects and making accidents less likely

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TO CONSIDER

• Identify ways your company could use 5S to improve its business performance and reduce wastes.

• State your 5S performance objectives in your area.

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Module 3 – 5S Audit Cycle

• Planning & Preparation

• Performing the 5S Audit

• Audit Report

• Follow up audit

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Module 2 – Auditing 5S Activities

• Uses and Objectives

• Auditors and Patrol Teams

• Auditor Independence

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What is the purpose 5S Audit

• To determine if 5S requirements are being met.

• To ensure 5S activities supports the organizational goals.

In your syndicated teams, state the main reasons for a 5S audit?

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Why Should Your Business be an Integral Part of 5S?

•List down the reason why your business should be an integral part of 5S initiative?

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5S Patrol Team • Managers, foremen or line leaders are entitled and both can be

responsible for 5S in their area - as patrolman.

• Chairman – Manager appointed

• Two patrols could check a same sector. Patrol planning needs to be done

• Generate audit checklist, criteria, measurement, analysis, report

• Committee chairman (Manager) summarizes audit results to be displayed and distributed on a timely manner

• Ensures system is maintained and effective.

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5S Auditor Independence

The internal audit activity must be independent, and internal auditors must be objective in performing their work. Independence

Objectivity

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Performing the Advanced 5S Audit An auditor must focus on the following when performing the audit:

5S System Compliance Are Procedures Being Followed? Verifying Procedures and Guidelines Activities Are Recorded Effectiveness of the 5S Program Opportunities For Improvement

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Audit Triangle

Question

Check Observe

Performing the Advanced 5S Audit

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Module 4 – Audit Checklist

• Purpose of Checklist

• Checklist Preparation and parameters to measure (Excel Spreadsheet)

• Scoring Mechanism (Excel Spreadsheet)

• Graphical presentation of data and analysis (Excel Spreadsheet)

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Purpose of Checklists

Organises planning and approach

Assures thoroughness and consistency

Identifies essential points to be examined

Identifies necessary evidence/samples

Cross reference to standards identified

Maintain audit direction

Keep it simple Keep to the requirements/facts Look at something Look for something

- approvals - tolerances - identifications

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Scoring Mechanism

Workshop

1. In your teams, review the sample scoring method given to understand how it works. (Attachment)

2. Based on the sample given, design a scoring method that will measure the performance of 5S program in your workplace.

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Module 5 – Audit Reporting and Follow up

• Audit Reporting and conclusion

• Auditors Responsibility

• Improving audit effectiveness (Corrective actions and preventive actions)

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Audit Report

The report should be a complete, accurate, concise and clear record of audit and should include following:

• Audit Objectives

• Audit Scope

• Identification of audit team leader and members

• Dates and places where activities were conducted

• Audit criteria (scores) and checklist

• Audit Findings

• Audit Conclusions

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Improving Audit Effectiveness (CAPA)

• Root Cause Analysis (Why-Why Analysis)

• Recurring issues.

• Measurement.

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Conducting a