Advance 5S Audits - INSOL Consultancy Sdn · PDF fileAdvance 5S Audits Improving and Sustaining The Performance Of An Organization ... •Generate audit checklist, criteria, measurement,

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