IED-GE-OC-FO-102

Rev.0
DEPT:______________________________________
AREA/SECTION:______________________________________ DATE:_________________________________
YES (/) NO (X)
PRODUCTION AREA - ENTRANCE (Note: Applicable for food facilities)
1 With hand washing area, properly equipped with soap and hand dryer.
2 With footbath sufficient with width, length and height to disinfect lower half of
boots.
3 Are free from insects and pests.
4 Area free from insects and pests.
5 With proper signages.
RACKS/ OPEN SHELVES
6 Are free from dust, stains, cobwebs, spillage, rust and are well-maintained.
7 Are labeled properly.
8 Items stored inside drawers are properly arranged.
9 Items stored match the identification of label.
10 No food and personal items stored.
CABINETS / TOOL BOX
11 Are free from dust, stains, cobwebs, spillage, rust and are well-maintained.
12 Are labeled properly.
13 Items stored are properly arranged.
14 Items stored match the identification of label.
15 No food and personal items stored.
16 Closed at all times when not in use.
17 Tools and small instruments are cleaned and returned to designated storage after
use. No defective tools and small instruments.
WORKING TABLES
18 Are free from cobwebs, rust and are well maintained.
19 Are free from dust, stains and spillage after any activity.
20 Items on top of tables are kept clean and properly arranged and stacked when
not in use.
CONTROL PANELS
21 Are free from dust, stains, cobwebs, drippings, rust and are well-maintained.
22 Are properly labeled.
CONTROL PANELS
23 No items stored inside except for control panel manuals.
24 Panel doors are closed at all times except during maintenance and inspection.
SEATING UNITS
25 Are kept clean and in good condition at all times.
26 Nothing is placed on top of chairs
PARTITIONS
27 Are free from rust, cobwebs and well-maintained.
28 Nothing hanged on it except signage.
WINDOWS / DOORS / GATES
29 Are free from dust, stains, cobwebs, rust and posted materials.
30 Are in good condition at all times (including venetian blinds and curtains).
31 Doors and gates are free from obstructions.
32 Two-way doors are provided with directional signs.
33 Windows and doors provided with screen to prevent entry of flies and other
insects. (Note: For food facilities)
WINDOWS / DOORS / GATES
34 Doors are wide enough to ensure no contact between door jambs and means of
conveyance. (Note: For food facilities)
35 Doors are self-closing. (Note: For food facilities)
36 Doors are non-permeable. (Note: For food facilities)
37 Doors fit perfectly when closed. (Note: For food facilities)
FLOORS
38 Are free from litter, stains and drippings after any activity.
39 Are free from protrusions, nails, unsecured wires, cords and other obstructions.
40 Are free of slip, trip or fall hazards.
41 Safety markings are visible at all times.
42 No missing or damaged tiles. No peeled off epoxy paint.
43 No missing canal covers/strainers.
44 No clogged drains and stagnant water.
45 Easy to clean. (Note: For food facilities)
FLOORS
46 Made up of non-slippery ceramic tiles, cement or synthetic materials. (Note: For
food facilities)
47 Free of cracks and indentation. (Note: For food facilities)
48 Junction with wall is rounded. (Note: For food facilities)
WALLS
49 Are free from stains and cobwebs.
WORKPLACE STANDARDS
CONFORMS ?
REMARKS/STATUS
5S AUDIT CHECKLIST FOR SHOPFLOOR
STANDARDS
IED-GE-OC-FO-102
Rev.0
DEPT:______________________________________
AREA/SECTION:______________________________________ DATE:_________________________________
YES (/) NO (X)
WORKPLACE STANDARDS
CONFORMS ?
REMARKS/STATUS
5S AUDIT CHECKLIST FOR SHOPFLOOR
50 Are free from memos, notes and notices.
51 No big cracks or holes.
52 No graffiti.
53 Only the following can be hanged/nailed on walls:
o work-related/decorative framed materials
o directional and instructional stickers/signs
o business and other permits
o religious items
54 Are non-permeable. (Note: For food facilities)
55 Are easy to clean. (Note: For food facilities)
WALLS
56 Are free of cracks and crevices. (Note: For food facilities)
57 With rounded corners. (Note: For food facilities)
CEILINGS
58 Ceilings, roof, insulation, light diffusers and air ducts are free from dirt, stains and
cobwebs.
59 No roof leaks and flaking of paint.
60 No missing or peeled off boards. No damaged insulation.
61 No cracked or missing light diffusers.
62 No busted light bulb.
AISLEWAYS AND PASSAGEWAYS
63 Are clear and unobstructed.
64 At least 28 inches wide.
65 Permanent aisles and passageways clearly marked.
66 Covers and/or guardrails provided when aisled or passageways are near open
pits, tanks, vats, ditches or similar hazards.
PLATFORMS / SCAFFOLDING
67 Working platforms at least 24 inches wide.
68 '4-inch toeboard provided along all sides.
69 Non-skid flooring provided.
70 Access gates self-closing and locking.
71 Equipped with standard guard rail if over 10 feet above floor.
72 Sound, rigid footing for scaffolds.
73 No accumulation of tools or materials.
74 No altering or moving of scaffolds in use.
STAIRWAYS
75 At least 22 inches wide.
76 Steps uniform in height and tread depth.
77 Are free from litter, dust, stains, cobwebs, rust and spillage.
78 Are free from unsecured wires, cords, obstructions and tripping hazards.
STAIRWAYS
79 Stairs having 4 or more risers are provided with standard hand rails on open
sides.
80 Open risers if less than 9-inch tread depth.
81 No damaged stairway risers and handrails.
82 Surface slip resistant.
83 Long flights broken by platforms.
84 Outdoor stairs have grating type treads.
EXITS/EGRESS
85 Sufficient exits for prompt escape (at least 2 exits from one area).
86 Exit doors not locked.
87 Routes and exits clearly marked.
88 Exits adequately illuminated.
89 Approaches to exits ubobstructed.
90 Flammables kept out of exits.
EXITS/EGRESS
91 At least 28 inches wide.
92 Open outward onto level floor.
ROADWAYS
93 Surfaces in good condition.
94 Sufficient width and vertical clearance provided.
95 Standard signs and marks present.
96 Rail sidings in good condition.
VENTILATION
97 Adequate means provided.
98 Air inlets and openings arranged to minimize escape of contaminants.
99 Enclosures provide continuous inward air flow.
100 Separators provided if air is recirculated.
101 Hoods draw air away from people and connected to exhaust system.
102 Ductwork made of non-combustible material, sealed and adequately supported,
Note: Any new item that will be hanged/nailed on walls are to be referred first to Admin.
Services for approval.
IED-GE-OC-FO-102
Rev.0
DEPT:______________________________________
AREA/SECTION:______________________________________ DATE:_________________________________
YES (/) NO (X)
WORKPLACE STANDARDS
CONFORMS ?
REMARKS/STATUS
5S AUDIT CHECKLIST FOR SHOPFLOOR
VENTILATION
103 Ventilation facilitates removal of objectionable odor, heat and moisture and entry
of clean fresh air. (Note: For food facilities)
NOISE EXPOSURE
104 Protection provided when sound levels exceed standard.
LIGHTING
105 Walking and working areas adequately illuminated during periods of occupancy.
106 Lighting fixtures clean.
107 Illumination level sufficient for detail of work performed; no shadowing or glare.
108 Lighting properly covered with non-glass material. (Note: For food facilities)
109 Emergency lighting of all exit routes not naturally lighted.
STACKING AND STORAGE
110 Aisleways and access paths clear and unobstructed.
111 Small or irregular shaped items properly blocked, interlinked, with proper
limitations in heigt of storage.
112 All stacks stable and secure against sliding/collapsing.
113 Proper drainage in storage area.
114 Storage area clean and cleared of foreign objects/materials.
STACKING AND STORAGE
115 Racks and platform load limits posted and observed.
116 With sufficient pallets, shelves and racks to hold usual inventory.
(Note: For food facilities)
117 Raw materials are stored according to prescribed storage condition.
(Note: For food facilities)
118 Proper separation of food and non-food items. (Note: For food facilities)
119 Stored materials are properly tagged with identification, delivery and expiry date.
(Note: Applicable to food facilities)
120 Follows FIRST IN, FIRST OUT system in issuing raw materials and finished
goods. (Note: For food facilities)
121 Separate storage area for raw materials and finished goods.
(Note: For food facilities)
122 Proper ventilation system. (Note: For food facilities)
123 Provision of pest and insect control. (Note: For food facilities)
124 Area facilitates smooth traffic for the reception and release of materials.
(Note: For food facilities)
125 No condensation. (Note: For food facilities)
MATERIALS HANDLING
126 Containers in good condition.
127 Pallets and skids of correct type and in good condition.
MATERIALS HANDLING
128 Materials on pallets are properly piled.
129 Chains, slings and ropes adequate for loads and in good condition.
130 Lifting equipment properly stored.
CHEMICALS AND FUELS
131 Tanks/drums made of steel or appropriate material, adequately supported,
grounded and bonded.
132 Limited to 2,500 gallons if above ground.
133 Tanks adequately venred and provided with pressure relief valves.
134 Adequate spill containment.
135 Proper spill absorbent materials provided.
136 Container corrosion prevention provided.
137 Temperature controlled to prevent boiling.
138 Adequate storage cabinets provided; fire resistant and vented.
139 Storage heated by means not constituting a source of ignition.
COMPRESSED GASES
140 Stored upright and secured against falling over.
141 Segregated by contents and legibly marked.
142 Caps in place and hand tight.
143 Protected against rust/corrosion.
144 Stored away from heat sources.
145 Stored away from stairs, elevators, and egress routes.
IED-GE-OC-FO-102
Rev.0
DEPT:______________________________________
AREA/SECTION:______________________________________ DATE:_________________________________
YES (/) NO (X)
WORKPLACE STANDARDS
CONFORMS ?
REMARKS/STATUS
5S AUDIT CHECKLIST FOR SHOPFLOOR
HAND AND PORTABLE TOOLS
146 Tools, electrical cords and air hoses in proper general condition.
147 Stored properly when not in use.
148 Guards and safety devices serviceable.
149 Electrical grounding or double insulation serviceable.
150 Power tools equipped with constant pressure switches.
151 Tool retainers installed on pneumatic tools.
152 Adjustment correct.
HAND AND PORTABLE TOOLS
153 Load rating sufficient for work performed.
MACHINE TOOLS AND GUARDING
154 Mechanical power transmission guarded.
155 Pinch points, in-running nip points, and points of operation guarded.
156 Fixed guards secured in position.
157 Interlock guards operative.
158 Automatic guards properly adjusted.
159 Operating controls guarded against inadvertent actuation, locked and key
removed when not in use.
160 Emergency stop buttons operational, correctly positioned, labeled, and color
coded.
161 Isolation and lock-out provided for servicing.
162 Guards provided for rotating parts, chips or particles, sparks, kickbacks, etc.
163 Operator and service manuals available.
CONVEYORS
164 Gears, shafts, pulleys guarded on nip points.
CONVEYORS
165 Drop guards installed to catch falling material.
166 Emergency stop controls adequately located and operational.
PRESSURE VESSELS
167 Meters and controls located on operating floor.
168 Safety valves operational.
169 Drains clear and freeze protected.
170 Inspection certificate/label appropriate to type.
171 Pipes, connections, vessels free of dents, notches and severe scratches.
172 Shields, platforms and landings as appropriate.
VALVES AND MECHANICAL CONTROLS
173 Are color-coded and properly identified with water-proof labels.
174 Operational
175 Readily accessible.
PIPELINES
176 Are color-coded for identification of hot and cold water and steam.
177 Pipelines for hot water and steam are properly insulated.
178 Are properly marked and self-draining.
SIGNS AND TAGS
179 Hazard warning, directional and informational signs and tags used where there
are immediate dangers, potential hazards, or there is a need for general
instructions.
180 Signs and tags consistent in use throughout the facility.
181 Tags affixed to all defective equipment not secured against use.
COLOR CODING
182 Red color coding used to indicate immediate danger.
183 Yellow color coding used to indicate changing conditions.
184 Orange color coding used to indicate areas under modification, hazardous parts
when guards removed.
185 Green color coding used to indicate safety insructions and first aid equipment.
186 Blue color coding used for general information signs and tags.
187 Color coding systems used to indicate fluid and gas system contents.
MATERIALS LABELING
188 Standard labels affixed to all containers of hazardous substances in storage and
use.
189 Standard labels affixed to vehicles transporting hazardous materials.
190 Labels legible and visible.
MULTI-PURPOSE TANKS
191 Are free from dust, stains, leaks, cobwebs, rust, unofficial stickers and well-
maintained.
192 Are properly labeled.
193 No items placed on top and beneath.
194 Equipped with level controls to prevent overflow.
MACHINERY AND EQUIPMENT
195 Are free from dust, stains, leaks, cobwebs, rust, unofficial stickers, unnecessary
drippings of oil or grease and well-maintained.
196 Are properly labeled.
197 No loose spare parts/tools/personal items lying on top, inside and beneath the
equipment.
198 Are in good operating condition.
MACHINERY AND EQUIPMENT
199 All moving parts are guarded.
200 Machine guards/doors are closed when machine is operating except during
trouble shooting.
IED-GE-OC-FO-102
Rev.0
DEPT:______________________________________
AREA/SECTION:______________________________________ DATE:_________________________________
YES (/) NO (X)
WORKPLACE STANDARDS
CONFORMS ?
REMARKS/STATUS
5S AUDIT CHECKLIST FOR SHOPFLOOR
201 Are installed at a minimum of 12 inches (greater distance for large equipment)
from walls, support structure and other stationary structure. (Note: For food
facilities)
202 Equipment and instrument location facilitate one-way process flow.
(Note: For food facilities)
203 Equipment and instruments/accessories are made up of non-corrosive materials.
(Note: Applicable for food facilities)
204 Facilities and equipment do not transmit toxic substances, odor and taste to
products. (Note: For food facilities)
205 Under controlled temperature as required by controlling authority.
(Note: Applicable for food facilities)
206 No material made of wood and breakable glass. (Note: For food facilities)
APPLIANCES
207 Are free from dust, stains, unofficial stickers and well maintained.
ELECTRICAL
208 Switches and outlets are clean and operational.
209 No broken switches and outlets.
210 No hanging connections, exposed or faulty wiring.
211 All equipment and appliances must be turned off and set aside after use.
212 Wiring of equipment and appliances are properly laid out. No octopus
connections.
ELECTRICAL POWER SYSTEMS
213 High voltage and control panels closed and secured.
214 Control panels identified and accessible.
215 Wiring, insulation and fixtuers in good condition.
216 Explosion-proof fixtures provided in dusty or flammable vapor areas.
217 Flexible cords free of splices.
WARNING SYSTEMS
218 Fire/Emergency alarm systems operational.
WARNING SYSTEMS
219 Hazard warning systems on appropriate vehicles and equipment.
220 Overpressure warning systems on pressure vessels.
221 Overtemperature warning systems on fired pressure vessels, hazardous material
storage, powered equipment.
222 Warning signs and devices for railway sidings available.
EMERGENCY INSTRUCTIONS
223 Operational placards/decals on emergency controls (on-off, open-close, etc.)
224 Emergency instructions at primary telephone in each work area.
225 Fire Hazard symbols on facilities containing hazardous substances.
FIRE PROTECTION
226 Potable extinguishers appropriate to type of materials readily available.
227 Extinguishers inspected monthly.
228 Fire hoses properly mounted and accessible.
FIRE PROTECTION
229 Fire equipment visibly marked.
230 Fire doors, lids and shutters in good condition with fusible links intact.
231 Sprinkler heads have minimum clearance from materials and furnishings.
232 Sprinkler master control valves accessible and locked open.
233 Personal protective equipment for fire brigade members in good condition.
EYE BATHS AND SHOWERS
234 Readily available and accessible in areas where caustic/corrosive chemicals are used.
235 Water supply provides 15 minute flush at comfortable temperature.
236 Proper signs and instructions.
237 Flushed frequently to eliminate contaminants.
FIRST AID KITS / STATIONS / EQUIPMENT
238 Located as prescribed by legislation and organizational medical policy.
239 Adequate materials and equipment available and properly located.
240 Electrical safety items included in high voltage areas.
DRESSING ROOM, TOILET AND WASH ROOM
241 Toilet equipped with the following at all times:
o toilet paper
o liquid soap in soap dispenser/container
o trash can
o mirror
242 Lavatories, urinals and toilet bowls are sufficient and kept clean.
243 Fixtures are in good working condition.
244 Well ventilated.
245 Entrance doors are closed at all times.
246 No faucet leaks.
247 With adequate water supply at all times.
248 Are free from cigarette butts, ashes and stains.
249 In good state of repair. (Note: For food facilities)
250 With disinfectant and hand dryer. (Note: For food facilities)
IED-GE-OC-FO-102
Rev.0
DEPT:______________________________________
AREA/SECTION:______________________________________ DATE:_________________________________
YES (/) NO (X)
WORKPLACE STANDARDS
CONFORMS ?
REMARKS/STATUS
5S AUDIT CHECKLIST FOR SHOPFLOOR
251 Does not directly open to working/processing area. (Note: For food facilities)
252 Adequate dressing rooms with lockers for personnel. (Note: For food facilities)
253 Provision for protective clothing (masks, hairnets, gloves) for plant personnel.
(Note: For food facilities)
254 Conspicuously posted instructions for personnel hygiene of plant workers. (Note:
For food facilities)
MEDICAL FACILITY
255 Presence of clinic for treating minor injuries.
256 With resident nurse or doctor.
SEWAGE AND WASTE DISPOSAL SYSTEM
257 Properly constructed drains.
258 With adequate traps and vents, catch basins, sump pits.
259 Drainage line of toilet is not connected with drainage line for plant.
260 All drainage properly covered.
261 No waste accumulation.
CLEANING TOOLS AND CHEMICALS
262 Are maintained in desired temperature condition and kept away from the
processing area. (Note: For food facilities)
263 Conveniently located in working stations. (Note: For food facilities)
264 With proper identification. (Note: For food facilities)
DRESS CODE
265 Employee ID is worn at all times within the company premises.
266 IDs are not dilapidated and without personal stickers.
267 PPEs (Personal Protective Equipment) are worn at all times.
268 Employees wear complete and clean uniform. Uniform is worn properly.
PERSONNEL HYGIENE
269 No wearing of personal accessories like jewelries, etc. (Note: For food facilities)
270 No sick workers alllowed to work.
271 Microbiological hand swab test regularly conducted.
TELEPHONE COURTESY
272 Telephone calls are answered within 3 rings.
273 The person answering the phone identifies himself or herself by saying, "Thank
you for calling (name of department)", Good Morning or Good Afternoon" as the
case may be.
274 The caller is advised if the call will be transferred to another
275 The person answering the phone takes note of the message, if the person he or
she is looking for is not available to take the call and ensures that message is
relayed.
OTHERS
276 Buildings are properly labeled.
277 Plant location free from objectionable odor, flying ash and dust and not subject to
flooding.
278 Surroundings are free from litter (excluding those coming from the plants) and
spillage (e.g., oil, grains, powder, etc.)
279 Solid waste is properly segregated.
280 Perimeter fencing to prevent entry of unauthorized persons and animals.
281 Scrap materials are properly piled on pallets and in designated areas.
282 Receiving and dispatching areas separated.
283 No smoking in prohibited areas in support of the Workplace Non-Smoking Policy.
General Remark or Recommendation:
A Total Number of Standards
B Less: Total Number of Non-Conformances
C Total number of Conformances ( C = A - B )
D WP Conformance Rating D = (C/A) * 100%
WP RATING Audited By/Date:
(% of Standards Complied With)
90-100% Exceeds Expectation (EE) Conforme/Date:
75-89% Meets Expectation (ME)
50-74% Needs Improvement (NI)
Noted By/Date:
WP Audit
Team Leader
WP CONFORMANCE RATING COMPUTATION
WP Auditor
Auditee/Dept
Representative