6 ‘S’ Audit – Practical Audit steps to implement each ‘S’

6 ‘S’ Audit is a tool to review the performance of 6'S Implimentation. Sustainability is a very important parameter to implementing lean manufacturing tools in any organization. To achieve a higher sustainability score audit is a mandatory requirement for any concept or new tool implementation.

Before you conduct an audit of 6 ‘S’. you need to understand what is 6 ‘S’ is and the basic awareness required of workers as well as staff of any organization. Review the article on 6 ‘S’ Implementation for basic understanding.

Practical Audit Steps:

1. Sorting Stage:

• Ensure the availability of a necessary item list with quantities (Workstation/Area Wise).
• Check for unwanted items at workstations, including equipment, parts, tools, and miscellaneous items.
• Verify the separation of needed and unnecessary items at workstations.
• Confirm the presence of a red tag zone, and check the red tag item register monthly.
• Conduct random checks for the periodic removal of unwanted items (celebrate Red Day).

2. Set in Order Stage:

• Identify fixed locations for necessary items.
• Confirm the proper quantity of necessary items.
• Check document availability for item and material locations (Workstation/Area Wise).
• Verify the nameplate availability for equipment types and their capacities.
• Ensure no items or tools are left on the floor.
• Label needed items appropriately.
• Verify floor marking visibility according to ANSI standards.
• Ensure a clear walkway without obstacles.
• Confirm the display of SOPs and work instructions (area/workstation-wise).

3. Shine Stage:

• Ensure proper cleanliness of the floor, equipment, and tools.
• Check for the absence of scrap, bullets, chips, and miscellaneous items.
• Confirm the availability of a cleaning checklist (daily/once in two days/weekly).
• Randomly identify sources of contamination.
• Check dustbin availability at workstations.
• Confirm the proper placement of cleaning equipment.
• Randomly check dustbin cleaning schedules.

4. Standardize Stage:

• Maintain documents such as necessary item lists, red tag registers, frequency tables, and cleaning checklists.
• Confirm the availability of the 5 'S' map (area/workstation wise).
• Check for abnormalities at workstations.
• Ensure the application of the just-in-time concept.
• Verify the understanding of checklist awareness.
• Periodically update KPIs.
• Randomly check display boards for cleanliness.
• Confirm the clear display of 5 'S' standards.
• Identify visual management tools upon completion of work.
• Check for the availability of process standardization documents (OPL, scheduled work).

5. Sustain Stage:

• Assess 5 'S' awareness among employees and staff.
• Note and implement improvements in the existing system.
• Plan and conduct periodic 5 'S' audits, maintaining records.
• Check for major deviations in the first four 'S' stages.
• Involve everyone in improvement activities.
• Ensure the perfect maintenance of 5 'S' documentation.
• Schedule regular visits from 5 'S' auditors.

6. Safety Stage:

• Check the availability and expiration date of fire extinguishers.
• Confirm the cleanliness of the floor, free of obstacles and slipping liquids.
• Ensure the use of proper personal protective equipment (PPE) by workers and staff.
• Daily random checks for near misses and updated accident graphs (area/workstation wise).
• Confirm the proper maintenance of fixed equipment and stand foundation bolts.
• Check the condition of electric cables, plugs, sockets, and electrical panels.
• Ensure proper storage of hazardous chemicals.
• Verify the labeling of emergency exits, assembly points, hazardous areas, walkways, material movement areas, and chemical storage areas.
• Conduct random checks for the availability of guards on rotating machine and equipment parts.