7s workshop-check-list

8/7/2019 7S workshop-Check-list

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TITLE: DOC. No.: FO A Q

Revision History & Distribution DATE: 30th Sep 2008DEPARTMENT: CLASSIFICATION:

DCC - Quality Assurance Form

Doc Title

Doc No. : CH A P 023 7'S NON - CONFORMANCE AUDIT C

REV Date Modification History

A 29-Jan-2007 Initial release

B 14-Feb-2007 Target NC'S/ Week - 5 Changed to Target NC'S/ Week - 20

C 02nd May 2007Target NC'S/ Week - 20 Changed to Target NC'S/ Week - 5

D 30th April 2008One more closure status column has been added.

E 06th May 2009

F 25th Aug 2009

G 03rd Sep 2009

H 26th Oct 2009 In 7s Office committee check list Point no. 24 & 25 has been repeated.

APC MGE logo changed to APC by Schneider Electric & in reference prohas been added. Department Name has been changed to IRC / Product

Whole Check List template has been Modified & modified with addingWorkshop daily, Office Daily, Committes for workshop & office

15days Date Column has been added to save Paper Cost & added oneCA-PA


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Distribution List

Department No Of Copies

Mfg Technology

Facility

Human Resources

Production

NPD

Purchase

Quality

Plat FormTest Engineering

Warehouse

Opex

IT

Employees Service


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011 REV NO. C

PAGE 1 of 1

REFERENCE:

PR A Q 010

HECKLIST

Initiated By Approved By

Cell Trainers

-

Arun kumar Raju

-

Arun kumar Raju

-

Cell Trainers

-

Sumana Sundara Rajulu

Ganesh Jaykanth Devdas

Hence revised Suman

cedure numberion

different Suman Dev &Jaykanth

Ashish &Devdas

Sheet known as

Ashish &Devdas


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Special Instruction

Soft Copy controlling


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TITLE: DOC NO. CH A P 023

7s Workshop Daily/Weekly/fortnightly DATE: 26th Oct 2009 DEPARTMENT: Warehouse CLASSIFICATION:

All CH

Sheet No. 1 Cell

Factory Stage Audited by & ID No

Sector Shift

7S Sl No Description 10-Mar 11-Mar 12-Mar 13-Mar 14-Mar 15-Mar 16-Mar

Sort

1

2

Straighten 3

4

Shine

5

6 Are cleaning materials easily identified,designated place and available whenever needed

7

Standardize

8 Are all the movable trolleys and machines have clearly marked area for storage when not in use

9

10 No useless parts, tools, documents : respect of allocated areas.

Su

stain

11 Daily used documents are identified and updated. No obsolete documents are found in the work Place.

12

13 SIM is implemented and respected.

Safety

14

15

16

17

18

SaveEarth 19

20

Total Score

7s Score for the Day

7s Score Calculation Formula = (Total Score/20)/5*100. 20 is nothing but the total no of Audit Points applicable

Note: If Something is not applicable in your Area, then Mention as N/A, Also reduce the No of Audit Points while Calculation

In Date of Auditing column, We need to enter the Dates (Eg : DD/MM/YY - 28/08/09)

Use CA-PA Sheet for Non Conformance Entry

1 7s System Available But not Followed

2 Applied at some areas and are being standardized

3 Partially Applied in Hidden Areas

4 Fully Implemented in Hidden Areas

5 No Opportunity for improvements as results are sustained for 6 Months in Management Audit

The Workbench is clean, No external item is present on the work station (External items include Dust,Dirt ,Unwanted objects, machines which are not frequently used ) including under the table inside drawersand in hidden areas like behind the racks etc,

Work tools are available and identified and stored in proper area. All PPEs/Work instructions are kept inproperly marked places. All tools required for the activity is only available at workbench.

All tool boxes and material stored at the work area are marked and identified.There is no unidentifiedobjects in the work area. Place for every thing is defined and respected

All documents and parts are identified and there are proper place to store /keep them. (No paper/books etcunder the table ,inside machines, over feeders etc)

PPE s are found in proper place, no PPE found lying around different areas. All PPEs ,tools , parts,equipments stored are in USABLE condition

All the equipment ,parts ,work bench etc in the area are clean and usable (no abnormality likeloose,open,leaking,come out ,open holes)

Do all the racks/storage bins/work bench/furniture/instructions /files/file numbering and storage /displaysystems look same at different cell/sectors

The 7S KPI's are updated and managed in SIM.All the employees know the 7S concept and score of morethan 90% for more than 6 months.

Safety protections are used, are in good condition and ESD certified ,ESD and equipment safety checklistsavailable and completed. No safety interlock is bypassed

Free passage, no carton, trolleys/racks and no pallets on the pathways. The pathways and storage is clearlymarked and safety equipment are not blocked.

Safety & Ergonomic precautions for each stage identified and visually depicted, exit routes are clearlymarked and safety procedures ,evacuation method known to all and displayed properly.

All the lifting and transportation units have working load clearly indicated and certified by competent

authority .

All the electrical panels are securely closed ,no hanging wires and cables, all the points are identified and allthe emergency stops are clearly marked.All guages and instruments /testing modules are caliberated andsecure.

There is no spillage /overflow of material or scrap on the ground or on the workstation, waste material iscollected every hour

There is no emission of harmful gases or chemicals in the work area, waste material is segregated at source(Plastic,Metal,heavy metals etc)


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7s Office Daily/Weekly/fortnightly DATE: 26th Oct 2009

DEPARTMENT: CLASSIFICATION:

All

Sheet No. 2 Cell

Factory Stage Audited by & ID No

Sector Shift Dat

7S Sl No Description

Sort

1

2

3

Straighten

4 All documents and office items are located at the point of use based on frequency of use.

5 Common areas ,aisles are identified with clear responsibility

6 All shelves ,drawers are properly identified with responsibility known

Shine

7 Desks are empty before starting on the evening and PC shut down at the time of leaving office

8 It is visually obvious what is good what is not good ,what belongs to that area and what does not

Standardize 9

10

Sustain

11

12

13 Regular 7 s helth check is done by the Senior people every month and action plan made

Safety

14 All persons are trained on safety and ERT team trained for handling safety equipments

15

16

SaveEarth

17

18

Total Score

7s Score for the Day

7s Score Calculation Formula = (Total Score/18)/5*100. 18 is nothing but the total no of Audit Points applicable


In Date of Auditing column, We need to enter the Dates (Eg : DD/MM/YY - 28/08/09)

Use CA-PA Sheet for Non Conformance Entry

Score Scoring Guidelines0 No Concept of 7s

1 7s System Available But not Followed





Area is clean, no item on on the window ledges, empty bins ,under the tables ,on the floor. No broken/damaged furniture .

No junk drawer or cupboard in the area ,no junk papers ,notices obsolete documents ,no broken orobsolete furniture ,sample etc in office a RED tag area exists

No extra stationary,ie if stationary is easily available supply in drawers should not exceed 2 weeks, nodouble markers/stapler/punching machines etc

Respect of identification system for documents and files. Proper 7 S is maintained for the files anddocuments and documentation rules are standard.

All the common and personal cupboards and drawers identified ,objects can be found without opening thedrawer/cupboard. All files/document storage is standard in all offices.(same color= same thing)

The main daily used documents, are updated, and no obsolete documents are found on the tables, all the

notice boards are standard ,telephone/computer places are marked

7S activity is done as per standard check list every day ,7 S scores are displayed and 7 S is part of dailydiary and SIM events

ERT persons identified in the office area ,Emergency exits clearly marked and evacuation route is visual.None of the aisles and safety equipments available in office are blocked

Safety policy ,safe and ergonomic working methods are displayed and visual. All Departments have safetymanual.

All the people are aware of the environmental impacts of the processes, people show their awareness byreducing electricity/water consumption etc.

Classification of hazardous/non hazardous waste available and procedure of clearing the wastes andsanitation is effectively done


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7s Workshop Daily/Weekly/fortnightly DATE: 26th Oct 2009

DEPARTMENT: CLASSIFICATION:

All

Date Non conformance CA / PA Closure date Date


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TITLE: DOC NO. CH A P 023 REV NO. H

7s Workshop Committee Monthly DATE: 26th Oct 2009 PAGE 1 OF 2

DEPARTMENT: CLASSIFICATION: REFERENCES:

All CHECKLIST PR A P 027

Sheet No. 3Sector Date of Audit

Cell Stage Audited By & ID No

7S Sl No Description Score Non-Conformance CA / PA Date of Closure

Sort

1

2

3

4

5

SetinOrder

6

7

8

9

10

Shine

11

12

13

14

15

16

17

18

Stan

dardize

19

20

21

22

Only the required spare parts, materials, WIP(in MPH (> 2 pitchtime), etc. are present at the workstation. Items not required tomake the current product are removed from the workplace.(Checkfor hidden areas also ie under work stations,behind pillars

Only the required tools are present at the workstation. Items notrequired to make the current product/or carry out the current job areremoved from the workplace.

Only the required paperwork(files /documents/information ispresent at the workstation. Out-dated or otherwise unnecessaryposters, memos, announcements, reports, etc. are removed fromthe workplace.

Only the required equipment is present at the workstation. Allobsolete, broken or unnecessary equipment, shelves, lockers,workbenches, etc. not required to make the current product isremoved from the workplace.

Only the required furniture is present at the workstation. Allbroken or unnecessary chairs, shelves, lockers, workbenches, etc.not required to make the current product is removed from theworkplace.(also check for broken window panes ,damagedmats,damag

Work cells are clearly defined ,Locations for containers,boxes, bins, WIP, materials,wastes etc. is clearly defined bypainted lines,colour codes and properly labeled (part number,quantity, etc the bins should have indications which will show clearly

Tools have a designated storage location that is within reach of theoperator for that stage based on frequency of use (Daily tools near

operator in tool shadow box). The location is properly labeled andtools can easily be identified if absent.

Paperwork ( WI's and communication boards ) is properlylabeled and has a clearly defined and labeled location that is visibleto the operators and away from work surfaces.

Equipment is clearly identified (numbered, named, color coded,etc.) and placed in a properly identified location. Criticalmaintenance points and critical parameters are clearly marked. (Onthe machine /available near the machine)Equipments like trolleys

Furniture is clearly identified (numbered, named, color coded, etc.)and placed in a properly identified location. (Furniture includesbins,racks,cleanining items etc)

Containers, boxes, bins, etc. are clean and not cracked, torn, orotherwise damaged. They are neatly stacked.

Tools are kept clean and in good working order. Where possible,tools are stored in a manner to keep them clean and free from risk ofdamage.

Paperwork is not torn, kept clean and protected from dirt.

Work surfaces (machines, workbenches, dies, and otherequipment including electrical boxes) are clean and painted and arein good condition.

Floors are free from dirt, debris, oil, parts, hardware, empty boxes,packaging material, etc. Drains (if required) are properly located andunclogged.

Walls, partitions, railings,floors etc. are painted and kept clean.

There is a schedule showing times, frequency and responsibilitiesto clean areas of the workplace such as windows, corners, walls,doors, top of cabinets, etc.

All cleaning equipment is neatly stored and is readily availablewhen needed.

Tools, equipment, paperwork, furniture, etc. are stored neatlyin designated areas and are returned immediately after each use.

Documents are labeled clearly as to contents and responsibility forcontrol and revision. The date and revision number are clearlyvisible. The document storage is standardized in all areas includingsupport functions.

Equipment maintenance records are visible and clearly statewhen maintenance last occurred and when next maintenance isscheduled.

The results of the previous audit are posted and clearly visible tothe entire team.


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23 Areas for improvement identified during the previous audit havebeen completed.


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TITLE: DOC NO. CH A P 023 REV NO. G

7s Workshop Committee Monthly DATE: 03rd Sep 2009 PAGE 2 OF 2

DEPARTMENT: CLASSIFICATION: REFERENCES:


Sustain

24

25

26

27

28

Safet

y

29

30

31

32

33

34

35

36

37

SaveEarth

38

39

40

TOTAL

Score

Score Calculation Formula = (Total/40)/5*100. 40 is nothing but the total no of Audit Points applicable


Score Scoring Guidelines

0 No Concept of 7s

1 7s System Available But not Followed/respected in allareas





Daily assessments realised by operatorsMonthly audits realised by management staff

Each employee (including temporary workers) is trained,rules respected and is involved in continuous improvement

Time and resources are allocated to 5S activities (e.g. designateddaily/weekly clean-up time, 5S team leader, etc.)

All operators, team leaders, supervisors, etc. are assigned5S activities to be completed at least once/week

5S is managed in SIM: indicators, suggestions, action plan5S Methodology is encouraged and valorized The team takes the

initiative to make improvements to the workplace that werenot

identified during the last 5S audit.

Tripping dangers such as electrical cables, obstructions tomovement ,pipes ,hanging wires and hoses etc. are removed fromstanding/walking areas.

Work areas requiring personal protective equipment are clearlylabeled and place of keeping PPE is defined.

Stop switches and breakers are highly visible and located foreasy access in case of emergency.In no case they are covered andlocated at inaccessible areas.Panels/doors of switchgears cableentries are secured as per standards.

Fire hoses, fire extinguishers and other emergency equipmentare prominently displayed and are unobstructed.

Working conditions are ergonomically friendly. Tools are stored

at appropriate heights, lift assist devices are provided wherenecessary, etc.

The workplace layout accomodates easy exit in case ofemergency.(Evacuation route is not complicated /Zigzag )

Walkways and vehicle paths are clearly identified andunobstructed. Exits are clearly labeled and unobstructed.

All personal protective equipment is maintained in sanitary andreliable condition and is properly stored in a easily accessible andlabeled location when not in use. The First aid box and emergencycupboards are available in proper form.

Equipment safety concerns are clearly identified. Safety guardsare painted, in good working condition and provide adequateprotection.

Product waste (e.g. shavings, containers, liquids, wrappers, etc.) isconsistently and often cleaned up and removed from theworkplace.Including other wastes like dross /Acids /CFC etc whichare not environment friendly show a reducing consumption level.

Preventive measures have been implemented based on rootcause analysis of the problems found during daily audits to ensurethe workplace meets 5S guidelines (e.g. systems that do not allowwaste to accumulate such as containers to collect product debris

The work environment satisfies the requirements of the work beingperformed. Lighting (brightness and color), air quality, temperature,etc.


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TITLE: DOC NO. CH A P 023 REV NO. H

7s Office Committee Monthly DATE: 26th Oct 2009 PAGE 1 OF 1DEPARTMENT: CLASSIFICATION: REFERENCES:


Sheet No. 4Sector Date of Audit

Cell Stage Audited By & ID No

7S Sl No Description Score Non-Conformance CA / PA Date of Closure

Sort

1

2

3

4

SetinOrder

5

6

7

8

Shine

9

10

11

12 Information board, documents , files are clean and maintened

Stand

ardize

13

14

15

16

Sustain

17

18

19

20

Safety

21

22

23

SaveEarth 24

25

TOTAL

Score

Score Calculation Formula = (Total/27)/5*100. 27 is nothing but the total no of Audit Points applicable


Score Scoring Guidelines

0 No Concept of 7s

1 7s System Available But not Followed/respected in allareas

2 Applied at some areas and are being standardized3 Partially Applied in Hidden Areas



There are no unnecessary office furniture or equipment,

substucture, office furniture and equipment are in good conditionSpace is optimized (dimension of areas, lay-out )

There are no unnecessary equipments or supplies: equipments andfurniture are in good conditionMutual cupboards / Mutual files are optimized (surface / volume )

There are no unnecessary items (peripheral, supplies, testedparts ...: personnal objects for decor are accepted but limitedThere are no personnal equipment redundant with mutual one

There are no unnecessary information or documents: documentsand files are in good conditionThere are no personnal files redundant with mutual one

Different areas (aisles -work spaces...) are defined (marqued ifpossible) and set in orderOffice is identified and people are located on the area

Equipments, files, furniture are appropriately located: easy to find,easy to place: locations are identified and arranged per layoutSpecific cleaning equipment is arranged per layout

Files, furniture, equipements and accessories (test parts for ex)are appropriately locatedIn absence the setup desk is free of document or file

Documents and files are identified and appropriately locatedInformation boards are set in order: visual, easy to understand

The floor is clean and maintained continuouslyWalls, windows, ceilings, substructure... are clean and inspectedperiodically

Clean and Preventive Maintenance (if appicable) is organized andrespectedCleaning is facilitated (no cable on the floor, display cabinets )

Desk, cupboards, equipments are clean and maintenened: trash issortedCleaning tools are adapted and optimized

Safety rules / Evacuation plan are updated and applied5S standard is known and respected: VISUAL

Visual management is in place: anyone can distinguish normal andannormal

SIM standards(event cycle, staff diaries management ) are knownand applied

Communication board / SIM board are updated and visualPerformance indicators on Department are managed and updated

Each employee (including temporary workers) is trained, respectedrules and is involved in continuous improvement

Daily / Weekly assessments realised by teamMonthly audits realised by management staff

SIM is respected and continuously improved: action plan , diarymanagement, SIM meetings, red green analysis are respected

5S is managed in SIM meetings: Indicatorrs, Suggestions, Actionplan5S Methodology is encouraged and valorized

All persons are trained on safety and ERT team trained for handlingsafety equipments

ERT persons identified in the office area ,Emergency exits clearlymarked and evacuation route is visual. None of the aisles and safetyequipments available in office are blocked

Safety policy ,safe and ergonomic working methods are displayedand visual. All Departments have safety manual.

All the people are aware of the environmental impacts of the

processes, people show their awareness by reducingelectricity/water consumption etc.

Classification of hazardous/non hazardous waste available andprocedure of clearing the wastes and sanitation is effectively done