5S LEAD ASSESSOR – June 2018

5S
Assessment
Methodology

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 5S LEAD ASSESSOR – June 2018

5S Audit 5S Assessment
• Generally refers to • Generally refers to

Assessment by the assessment by

team or top
external agencies
management • Always followed
by
on its own system .
rating on a
• Followed by
standard
Scoring/Rating
• scale
• Mostly
Document
Document verification

audit is not ABK AOTS DOSOKAI

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 5S LEAD ASSESSOR – June 2018

Assessment Objectives

1To find actual 5.To Facilitate

status the process

2 To 4 To
the gap
assess improvement
provide
guidelines

3 To
identify
hidden issues
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 5S LEAD ASSESSOR – June 2018

Types of 5S Assessment

• Self Assessment *
1
3 Three
• Internal Assessment *
types of 2
Assessment
• External Assessment
3
* We call them as assessment because it involves
some rating work based on internal standards
within the organization

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 5S LEAD ASSESSOR – June 2018

Types of 5S Assessment

Self Assessment :

• Zone members carries out assessments at a stated

frequency in their own zone and keep correcting

their deviations

• Considered as one of the best habits towards

sustenance of Improvements

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Types of Assessment

Internal Assessment :
• Zone assessments of an organization that are
generally carried out by trained internal
auditors of other zones of the same
organization
• Generally It is done once in a fortnight /month
in any organization

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Types of Assessment
External Assessment :
• Assessment of an organization that are carried
out by External agency / Consultants .
• Generally it is done once in year or twice in a
year to get a 3rd Eye Perspective on the 5S
System implementation
External Assessment :
• It is done to get rid of stagnancy state , get
new
view points and directions to move / improve
the
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Stages of an Assessment
Assessor brings out
hidden issues
clearly to the
• Apart from management
• Starts checking
checking Assessment &
compliance and
Compliance and Assessment
•Compliance also start Reports attains
checking the adequacy , maturity
State
adequacy of Assessor start
• Assessor His assessment
system with the suggesting becomes a
observes the
standard check improvements value added
compliance to information to
list and provide
& suggestions the mgt.
the standard guidance
chk list

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 5S LEAD ASSESSOR – June 2018
Guidelines for Assessment
• Divide the area into sub areas or zones.
• Develop and use an appropriate check list for the zone
• Look for obvious and not so obvious conditions as per the
check list.
• Talk to the employees informally and make an
assessment of their involvement and motivation.
• All your senses should be tuned to sense and
collect observations
• Do not make sarcastic comments and avoid blaming
words or criticizing comments or arguments
• Ask leading, open ended questions to employees while

auditing.
• Don’t be rough and tough.
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5S assessment Check
list

It is a list of specific tasks that an assessor need to carry out in

connection with the standard check list and the type of

organization due for assessment.

A 5S checklist should be easy to use, relevant, specific,

friendly, and a way to promote further improvements.

It is used as both a learning and motivational tool.

As an assessor look for up gradation /modification/ of

check lists in the organization over

ABK AOTS a period of time
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Guidelines of Scoring
Option-1: (based on no. of deviations)
for example: on a 5 point scale
5 point scale(0-1-2-3-4)
You can award
4-No deviations
3-one or two
deviations
2-Three or four deviations
1-Five or six deviations
0-more than six DOSOKAI
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5S LEAD ASSESSOR – June 2018

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Some of the Documents to be considered during assessment:

1. 5S Manual
2. Red tag register – Disposal policies – Compliance records
3. SOP’s
4. Audit Check lists
5. Internal audit plan –schedule -Audit observations / Response by zones – List of
trained internal auditors
6. Documents supporting CSR initiatives
7. Cleaning schedule / Checklists
8. Improvement projects – Cycle time reduction projects – Fatigue reduction –
Kaizens – SGA’s etc.,
9. 5S Reviews – Meeting minutes – Review Effectiveness
10. Training initiatives - Records

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External Assessment
• It is a company wide assessment of 5S system to

be carried out preferably by an external agency or

an experts or consultants.

• It is also preferable to conduct external

assessment at least once in 6 months.

• Generally, these assessments are carried out

using a 1000 point Score Sheet.

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 5S LEAD ASSESSOR – June 2018

External
Assessment 1000 Point Scale
1. Leadership -100

2. Seiri - 200

3. Seiton- 200

4. Seiso - 200

5. Seiketsu - 150

6. Shitsuke - 150

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5S LEAD ASSESSOR – June 2018

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 5S LEAD ASSESSOR – June 2018

1000 point Score Sheet

Leadership-100
Seiri-200
Seiton-200
Seiso-200
Seiketsu-150
Shitsuke-150

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LEADERSHIP
*Clarity of 5S Organization Structure
*Roles&Responsibilities
*5S Vision&Objectives
*5S Logo and 5S Corner
*Regular Review
*General awareness on 5S at all levels.

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SEIRI
*Disposal Policy
*Red Tagging Procedures
*Status of Scrap yard
*Clutter free atmosphere
*External Area Maintenance

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SEITON
*Display Boards and Instructions
*Parking Areas for vehicles, material handling
Equipments,Office furniture, Machines etc.
*Floor marking, directional indicators
*Identification for office documents, pipelines,
fire Extinguishers.
*Identification for all stored items for easy
retrievability

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SEISO
*General cleanliness of office area and toilets
*Cleaning standards of machines in shop floor
*Cleaning responsibility matrix
*5 min cleaning and cleaning schedules
*Waste bin strategy
*General Impression while entering into the unit.

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SEIKETSU

*Standardization of procedures
*5S Corner is maintained with before/after
photos displayed and scores are also drawn
in Radar Diagram.
*Checklists for all areas
*Visual Control Devices
*Safety related issues
*Internal Auditing Procedures.

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SHITSUKE

*Regular training programs for updating

knowledge on 5S and induction Training
*Inter-departmental competition for 5S
*5S Champions
*5S teams engaged in Improvement Projects
*Impression from visitors
*Benchmarking with best 5S companies
*Show casing 5S practices to others.

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Assessment Criteria for

Sustenance Level & Model

Level

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o f
els on
v ati
5 • Model Level Certification
e
L fi c
3 rt i S
Ce

5 • Sustenance Level Certification

S

5 • Basic Level Certification

S
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 5S LEAD ASSESSOR – June 2018

5 • Basic Level
S Certification
1000 Point Scale

1. Leadership -100

2. Seiri - 200

3. Seiton- 200

4. Seiso - 200

5. Seiketsu - 150

6. Shitsuke - 150

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 5S LEAD ASSESSOR – June 2018

For evaluation of Model and sustenance status level ,in addition to

Sustaining the Basic 5S systems the audit emphasis is given to the
following governing factors:
1. Leadership
2. Basic 5S
3. Standardization
4. Total Employee Involvement
5. Improvement Projects
6. Contribution to Society (Beyond Boundaries)

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Accordingly a new audit check

list was designed to evaluate
Model Level / Sustenance Level
audit as shown in the adjacent
table.

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Qualifying Criteria
Model Level Status

Qualifying Criteria
Sustenance Level Status

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sly
i ou s 5S System starts paying back to
nsc iou
co sc ge the company
n  800
Un co sta  5S -Model Company

651 to 800
l y ge
Three Stages of

s
iou sta Very Active 5S
c s
Practice

s
n iou
o
C sc 451 to 650
o n
c Active 5S

sly 301 to 450

o u us 5S Just started
ci io
n s sc
o o n ge
C nc ta Up to 300
U s
5S not started

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Key Points
To become a
Good Assessor

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1 • Look for Frankness & Openness .

2 •Believe, that, you are there to only see the facts and details of 5S practice and observance; you are not there to criticize their practices . Very
important

• You should aim to make the audits as

3 a value adding exercise; keep guiding
them for higher level of improvement
planes

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• Look for 5S conceptual understanding

percolation down to all levels of the

4
organization; interview some
employees at random, pl remember,
your input to the organization will
help them to plan their way forward.
• Focus on safety measures  (fire safety,
first aid) and emergence preparedness

5 (emergency exits, emergency

assembly areas, etc). Remember
‘Safety’ is the very immediate
improvement coming out of 5S system

6
• Look for understanding of the 5S
System in its true spirit and not as
cosmetic understanding
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• Focus on How the organization is

serious about extending the 5S
7 beyond its boundaries (Employees
family, schools, hospitals, panchayat, 
public places, etc.,)

8
• Look for 5S is coverage in peripheral
areas and security as well. Also Stores’
and maintenance.

9 • Method of red tagging, review and

disposal system; scrap disposal policy.

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• Look for whether management review

10 is taking place on 5S performance and
look for effectiveness.

11 • Indicate Kaizens for improvement as a

result of 5S

12 • Look for capturing benefits out of 5S

System implementation

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