Plant Name: Neel 2 & 3

Audit Zone No.:

A

'MGS' 1S, 2S (5S) Audit Check List (Shop Floor Area)

Zone Leader: Mr.
Level of Judgment Max Marks

Area:

Auditor / Plant / Team/ Colour Name: Gaurav Dwivedi

Level-1
Not being Practiced at all.

Date of Audit: 18/2/2010

Criteria for Score level-2
Practiced but not thorough ( Partially Done)

Level-3

Level-4

Level-5

Criteria for deciding the Level

Can be Created Model Horizontally considered as a Areas within Deployed Role Model for the Zone within the Zone other Zones

Marks Allocation 1S Sorting Out

1 2 3 4 5 6 7 8 9 10 11 12 13 No leakages of air, water, oil and gas and pilferage of material in any form, excessive noise, spatters, fumes, bad odors etc. Rack height, Inventory pile and other stacking to be below 6ft Height: Nothing on the top of the rack, under the table , under the machine, below the staircase etc.
TOTAL MARKS ACHIEVED FOR 1S SCORE FOR 1S = Score / 260 * 100 (%)

0 0% 20 20 20 20
20 20 20 20 20 20 20 20 20
260

5 25%

10 50%

15 75%

20 100%

Entire Plant is divided in 'Zones' & 'Sub-Zones, updated list with zone owners available. 'Zones', 'Zonal & Central Red Tag Rack / Area', are identifiable Computer & Desk Surface is managed: all files in categorized folders, mail box sorted, desk has only items needed at that time Department Heads Participate in Surprised 5'S' checks regularly. There is system for periodic SORTING & Control of Unwanted / Surplus Material / Documents / Records, RED TAGGING SYSTEM understood by ALL and followed, Autonomous '1S' Schedule displayed & followed for work stations Nothing on Floor, Out Skirt of the factory , Roof ,Walls / Windows sill etc :No raw materials, work-in-process, finished goods, tools or gauges, documents/files are stored directly on floor No Cigarette butts, scrap of paper, tools, parts, bins, chips, oi Scrap & Red Tagged item Disposal System & Management : Scrap & Red Tagged items are disposed off at a regular interval as per decided system (dust bins not overflowing) , Last Clearance Date , Next Due Date & person responsible is displayed & Followed. No mix up of two different kinds products: No mix up of OK ( Wanted ),Rejected ( Unwanted) Parts/ Mix up of scrap in scrap yard. No storage of unused/ excess parts like raw material, bought out parts, finished goods etc/ there is no misuse of components used as a tool like hammer etc. Regular Disposal of drums, grinding sludge, paint sludge, spent oil, used consumables welding rods, cutting tools, etc No storage of old machines , equipments , tools & fixtures, old Standards (not in use) , old Drawings/ parts ( obsolete), old documents( obsolete), old furniture( not in use), old racks inside the factory premise.

0 0

S.N. 1

2S Systematic arrangement (SEITON)

"There is a Place for every thing" Department Head Approved & Updated Layout plans / maps are displayed (for Gangway, Equipment, Furniture, Bins, Waste Bins, Trolleys, WIP, etc.) Locations for storage of the Parts, Documents, Stationary, tools , are defin "Every thing is in its place" Every thing is available in its pre decided locations as per approved layout plans and identified locations. Right component in right containers / pallets / Bins/ Trolleys / Drawers etc. with Visual Control. Nothing stored on All notices/ work instructions are displayed in neatly arranged manner. All data is updated All Notices / work instructions hang / paste within the board. All notices / work instructions displayed are clearly readable. No torn or soiled notices are dis Gangways are free of material, parts ,trolleys, empty bins etc. Gangways used for man and material movement, no zig zag movement of man & material. Equipments: There are no open / loose / broken wiring, panels, switches etc. Bus bar trunking, air and water lines & all cable connections are at right angle. There is adequate space for the operator and maintenance staff to service/ clean the equipment Effective FIFO ( First In & First Out) System is in place & practiced. Cleaning tools like Broom, Brush , Small Shovel , Tool for cleaning at Heights are kept with proper identification & at an appropriate location. people have been given training on 5S and they understand that purpose of 5S is NOT housekeeping but to organize work place to improve Productivity & Safety by eliminating Muda, Mura and Muri Electrical Wires Color Codes, Pipes Identification-Colour Codes/Identification of Gas/Liquid/Chemical/Hazardous Materials/Pressure ,Temperature/Direction of Flow/Wire and Wire Ropes/Visuals for all types of Gauges, Measurement Equipment/Recorders etc. Equipment Identification- Numbered, Labeled: Material handling Equipment / Trolleys / Bins / Waste Bins etc. Visual Capacities / Cycle time / WIP Quantity. Direction boards for Toilets, Canteen, dispensary, meeting Room , water coolers, different shops/ departments/divisions, Hazardous Areas etc are effectively displayed. Visualization for Targets and Status, direction of rotation of motors and other equipment , Control Boxes / Safe and Unsafe Zones etc. Work / Inspection tables: are having adequate lighting arrangement, identified place for keeping tools, instruments, gauges & display of work instructions.
TOTAL MARKS ACHIEVED FOR '2S' SCORE FOR '2S' = Score / 260* 100 (%) Score

0%
20

25%

50%

75%

100%

2 3 4 5 6 7 8 9 10 11 12 13

20 20 20 20 20 20 20 20 20 20 20 20
260

0 0

0.00

Plant Name:
Audit Zone No.:
A

'MGS' 5'S', Audit Check List (Office Area)

Area: Zone Leader: Auditor / Plant / Team/ Colour Name:
Level of Judgment Criteria for deciding the Level Marks Allocation 1S Sorting Out Max Marks

Date of Audit:
Level-1
Not being Practiced at all.

level-2
Practiced but not thorough ( Partially Done)

Criteria for Score Level-3

Created Model Areas within the Zone

Level-4
Horizontally Deployed within the Zone

Level-5
Can be considered as a Role Model for other Zones

0 0%
10 10 20 20 20 20 20 20 20
TOTAL MARKS ACHIEVED FOR 1S SCORE FOR 1S = Score / 160 * 100 (%)

5 25%

10 50%

15 75%

20 100%

1 2 3 4 5 6 7 8 9

Entire Office area is divided in 'Zones' & 'Sub-Zones, updated list with zone owners available. 'Department', 'Zone & Zonal Red Tag Rack / Area', are identifiable List of essential items along with Quantity needed to carryout the work is available & updated regularly Computer is managed: all files in categorized folders, mail box sorted. BG Head, Unit Head, Department Heads Participate in Surprised 5'S' checks regularly. Soft Picture / Video album of 'Before' and 'After' is maintained. There is system for periodic SORTING & Control of Unwanted / Surplus Material / Documents / Records, RED TAGGING SYSTEM understood by ALL and followed, Autonomous '1S' Schedule displayed & followed for work stations Nothing on Floor, Roof ,Walls / Windows sill etc : Books, documents/files are stored directly on floor No Cigarette butts, scrap of paper, samples, parts, etc are lying on the floor & scattered around the office premises. Desk is managed: Desk and Drawers have only items needed at that time. Parts, office tools, items do not touch each other in containers, trays, table drawers, etc. Clean free storage system is followed. All Items are retrievable in 30 Sec. No torn or soi No storage of old machines, old Standards (not in use) , old Drawings/ parts ( obsolete), old documents( obsolete), old furniture( not in use), inside the office premise. Cupboards, almirahs, racks, drawers are transparent .No documents pasted on walls, under the table glass, Calendar and Clocks visible to all

160

0
0.0

S.N. 1 2 3 4 5 6 7 8 9

2S Systematic arrangement (SEITON)

"There is a Place for every thing" Department Head Approved & Updated Layout plans / maps are displayed (for Gangway, Furniture, Computers, Printers, Photocopiers, Waste Bins etc.) Locations for storage of the Documents, Stationary, are defined based on P "Every thing is in its place" Every thing is available in its pre decided locations as per approved layout plans and identified locations. Right item in right Folder / Drawers / Shelf etc. with Visual Control. Nothing stored on top & behind of equipments All notices/ work instructions are displayed in a straight and neat manner. All data is updated All Notices / work instructions hang / paste within the board. All notices / work instructions displayed are clearly readable. Nothing is to be pasted on Wall Gangways are free of material, chairs etc. Gangways used for man and material movement, no zig zag movement of man & material. There are no open / loose / broken wiring, panels, switches etc.all cable connections are at right angle. Adequate lighting on work tables Documents and binders are stored in a orderly fashion with proper identification & Master list is in place with a view to have ease of retrieval & restoring 30 secs. Cleaning tools like Broom, Brush , Small Shovel , Tool for cleaning at Heights are kept with proper identification & at an appropriate location. Direction sign boards for Toilets, Canteen, dispensary, meeting Room , water coolers, different shops/ departments / divisions etc are effectively displayed. Autonomous 2 'S' check sheet displayed and followed by work station owner
TOTAL MARKS ACHIEVED FOR '2S' SCORE FOR '2S' = Score / 180* 100 (%)

0%
20 20 20 20 20 20 20 20 20 180

25%

50%

75%

100%

0
#DIV/0!

S.N. 1 2 3 Responsibility & periodicity of cleaning are clearly defined & Understandable & known to all.

3'S' Shine (SEISO)

20 20 20
TOTAL MARKS ACHIEVED FOR '3S' SCORE FOR '3S' = Score / 60* 100 (%)

0%

25%

50%

75%

100%

All furniture, Desk items, Windows, Curtains at work stations are shining as if new, work station looks like a 'showroom' All cleaning equipment and aids are stored in a neat manner and are kept with proper identification & at an appropriate location.; easily available when needed

60

0
#DIV/0!

S.N. 1 2 3

4'S' Standardize (SHITSUKE)

100 % people have been given training on 5S and they understand that purpose of 5S is NOT housekeeping but to organize work place to improve Productivity & Safety by eliminating Muda, Mura and Muri Every body has smart & tidy looks, uniform / dress is not dirty etc. Visualization of Standards of 1S, 2S and 3S so that anyone can detect non-conformance
TOTAL MARKS ACHIEVED FOR '4S' SCORE FOR '4S' = Score / 100* 100 (%)

0%
40 20 40 100 0.0

25%

50%

75%

100%

S.N. 1 2 Self audit for 5'S' is carried out at regular intervals

5'S' Self Discipline (SEIKETSU)

50 50
TOTAL MARKS ACHIEVED FOR '5S' SCORE FOR '5S' = Score / 100* 100 (%)

0%

25%

50%

75%

100%

Ownership and feeling 'My Zone'. Genuine concern for improving TEI in 5 'S', is visible in daily conduct. Uncomfortable when 1S, 2S, 3S Practices are not seen anywhere

100 #DIV/0!

TOTAL

Plant Name:
Audit Zone No.:
5-S DESCRIPTION

'MGS' 5'S' Audit Check List (Miscellaneous Area)

Area: Zone Leader:
CHECK POINT

Date of Audit: Auditor / Plant / Team/ Colour Name:

MAX MARKS 5 5 Marks Obtained

Roads, Roofs & Lawns No unwanted items 5 - Zero non compliance 3 - Two cases of non compliance. 0 - More than Two case of non compliance. Security Gate, Parking No unwanted records. Area, Medical Room 5 - Zero non compliance 3 - One case of non compliance. 0 - More than one case of non compliance. Availability of items such as soap, soap case as per Check Sheet Toilets 10 - Zero non compliance 5 - One case of non compliance. 0 - More than one case of non compliance. Roads, Roofs & Lawns Adequate lighting at proper places. Proper condition of the boundary wall and installations in the area. 5 - Zero non compliance 3 - Two cases of non compliance. 0 - More than Two case of non compliance. Security Gate, Parking Proper arrangement & condition of furniture. Proper lighting. Proper marking of parking area & proper parking of vehicles in the marked areas. Area, Medical Room 5 - Zero non compliance 3 - Two cases of non compliance. 0 - More than Two case of non compliance. Availability of Looking glass, Drinking glasses near water coolers. Proper condition of all equipments. Utensils, raw and Canteen & Pantry cooked food and other equipment placed at identified places. Proper storage of gas cylinders 10 - Zero non compliance 5 - Two cases of non compliance. 0 - More than Two case of non compliance. Condition of Taps - Metal shining, bent, mismatched/ symmetry, leakage. Glass/Mirror - Broken, Mutilated, cleaning, Toilets clear visibility, properly framed. Proper lighting with Sensors. 10 - Zero non compliance 5 - Two cases of non compliance. 0 - More than Two case of non compliance. Roads, Roofs & Lawns No oil / pit holes on Road. No piles of dust / garbage. No Water clogging. Clean drains 5 - Zero non compliance 3 - Two cases of non compliance. 0 - More than Two case of non compliance. Security Gate, Parking Cleaning of floor, racks, tables. Area, Medical Room 5 - Zero non compliance 3 - One case of non compliance. 0 - More than one case of non compliance. Clean floors, chairs, tables, windows. No water accumulation on the floor. Nothing is kept on floor. Wash basins / Canteen & Pantry cleaning arrangements are in place. 5 - Zero non compliance 3 - Two cases of non compliance. 0 - More than Two case of non compliance. Proper upkeep of plants, trees, grass etc. RWH, Horticulture 5 - Zero non compliance 3 - Two cases of non compliance. 0 - More than Two case of non compliance. Washbasin - Choking, Leakage, Spiting marks, dust at corners. No water, spiting, crazy remarks on Walls, doors & Toilets these are in proper condition 5 - Zero non compliance 3 - Two cases of non compliance. 0 - More than Two case of non compliance. Roads, Roofs & Lawns Effluent treatment system is in place. 5 - Zero non compliance 3 - One case of non compliance. 0 - More than one case of non compliance. Personal upkeep / hygiene of canteen workers. Use of uniform including cap, apron and gloves. All eatables and Canteen & Pantry equipment are stored in hygienic condition. Pesticide treatment / fly catching arrangements are evident are in place. Effective exhaust system. Suggestion box / book readily available. 10 - Zero non compliance 5 - Two cases of non compliance. 0 - More than Two case of non compliance. Exhaust System - No suffocation, good condition. Toilets 5 - Excellent . 3 - Good . 0 - Poor Security Gate, Parking Area, Medical Room Physical upkeep of guards. 5 - Zero non compliance 3 - One case of non compliance. 0 - More than one case of non compliance. TOTAL MAXIMUM MARKS MARKS OBTAINED

SEIRI

10

20
5 5

SEITON

10

10

30
5 5

SEISO

5 5

25
5 10

SEIKETSU

20
5

SHITSUKE

5
100 0

0 0

%AGE MARKS

Plant Name:
Plant Name:
A

'MGS' 6th 'S' 'SAFETY' Audit Check List (Shop Floor Area)
'MGS' 6th 'S' 'SAFETY' Audit Check List (Shop Floor Area)
Level of Judgment Criteria for deciding the Level Marks Allocation Safety Awareness Max Marks Level-1
Not being Practiced at all.

level-2
Practiced but not thorough (Partially Done)

Criteria for Score Level-3 Level-4

Created Model Areas within the Zone Horizontally Deployed within the Zone

Level-5
Can be considered as a Role Model for other Zones

S N. 1 2 3 4 5 6 People have been given formal Training on Safety

0 0% 20 20 20 20
20 20 120

5 25%

10 50%

15 75%

20 100%

People are using Safety Devices like protective glasses, gloves, Helmet, cap, ear plug, apron, safety shoes etc. where ever required People are aware about Workshop's Safety rules & Safety Precautions while working on machines People are aware about precautions to be taken in material handling People are aware about emergency exit / layout of the building People are aware about corrective action in case of emergencies, e.g. are aware about cutting off electrical Supply in case of Emergency
TOTAL MARKS ACHIEVED FOR Safety Awareness SCORE FOR Safety Awareness = Score / 120 * 100 (%)

0
0%

0
25%

0
50%

0
75%

0
100%

0
20 20

S N. 1 2 People are able to use Fire fighting equipment

Fire Fighting
Safety & Fire fighting equipments are available in pre fixed locations, as per approved layout. & Stored so that easily accessible
TOTAL MARKS ACHIEVED FOR Fire Fighting SCORE FOR Fire Fighting = Score / 40 * 100 (%)

40

0
0%

0
25%

0
50%

0
75%

0
100%

S N. 1 2

Safe Material Handling

Material and Tools are accessible with minimal twisting or extending the body and area for reaching the items is sufficient The operator does not frequently handle heavy and large objects. Tooling and equipment do not transfer excessive vibrations. The operator has the appropriate equipment and accessories to left heavy or encumbering loads or objects. Protecting fences are provided when there is a risk of falling objects.
TOTAL MARKS ACHIEVED FOR Safe Material Handling SCORE FOR 'Safe Material Handling' = Score / 40 * 100 (%)

40

0
0%

0
25%

0
50%

0
75%

0
100%

0
20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
300

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 All Machines are started after checking all points as per check list

Safe Working Environment

No material is accumulated in front of Electrical distribution box, Fire extinguishers, Safety exit etc. Safety Calendar is effectively displayed Gangways are appropriately marked as required Gangways are free of material, parts ,trolleys, empty bins etc. Gangways used for man and material movement, no zig zag movement of man & material. Appropriate size of Convex mirrors are fixed at blind turns There are no open / loose / broken wiring, panels, switches etc. Bus bar trunking, air and water lines & all cable connections are at right angle. There is adequate space for the operator and maintenance staff to observe safety while operating / servicing / cleaning the equipments. The floor is free from pits and is NOT irregular The noise level is monitored regularly and is within norms. The lighting level should be sufficient. Light sources should not be harsh or blinding. Access to mobile machine parts is protected by railings, guards, coverings, etc. Work with hand tools on a rotating areas is limited. Emergency stop devices are installed wherever there is risk. The First aid boxes are kept with necessary medicines availability ensured & are at kept at right place The Hazardous Gas cylinders are kept and maintained as per safety norms Direction boards for Emergency exit, dispensary, Hazardous Areas etc are effectively displayed. Caution display boards are effectively displayed. Visual indications for electrical cabinets, direction of rotation of motors and other equipment , Control Boxes / Safe and Unsafe Zones etc. Work Permit is obtained from competent authority before starting Non production job on Machines. Safety instructions are revised before starting the job
TOTAL MARKS ACHIEVED FOR 'Safe Work Environment' SCORE FOR 'Safe Work Environment' = Score / 300* 100 (%) Score

0 0.00