Standard Work · SOP

5S Audit Scoring And Follow Up Action Plan

A structured method to score the 5S condition of any work area, identify non‑conformances, and create an actionable follow‑up plan to drive continuous improvement and sustain lean gains.

Estimated Time

45 min

Difficulty

Intermediate

Regulation

Lean Standard

Version

1.0

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Purpose

This procedure establishes a consistent, repeatable method to evaluate 5S compliance in any workplace area. By combining a structured scoring system with a clear follow‑up action plan, the organization can identify gaps, assign corrective actions, and track progress over time. The goal is to systematically eliminate waste, improve visual order, and build a culture of sustained discipline.

Scope

This SOP applies to all production, assembly, warehouse, and support areas within the facility. It covers the full audit cycle: pre‑audit preparation, visual inspection, scoring per the five 5S pillars (Sort, Set in Order, Shine, Standardize, Sustain), red‑tagging of non‑conformances, and the formal documentation of a follow‑up action plan. It does not cover deep cleaning procedures or equipment maintenance tasks beyond the 5S scope.

Safety Precautions

PPEWear required personal protective equipment (safety glasses, steel‑toed boots, and any area‑specific PPE) throughout the audit.
LOTODo not open machine panels or remove guards. If a red‑tagged item is near moving machinery, coordinate with maintenance for lockout/tagout before handling.
ERGUse proper lifting technique when moving red‑tagged items; team lifts for loads over 20 kg. Keep aisles clear at all times.

Required Tools & Materials

Current 5S audit checklist (per area)
Scoring sheet / digital form
Area floor plan or zone map
Red tag forms & log
Digital camera or tablet for photo evidence
Clipboard, pen, and high‑visibility vest
Action plan template (paper or digital)

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Procedure: Step-by-Step

1 Gather Audit Materials. Obtain the current 5S audit checklist, scoring sheet, area map, red‑tag forms, and a tablet or camera. Verify that the checklist corresponds to the area being audited.

2 Conduct Visual Inspection. Walk the entire zone using the checklist. Assess each of the five pillars (Sort, Set in Order, Shine, Standardize, Sustain). Note specific examples of compliance and non‑compliance. Photograph deficiencies for evidence.

3 Score Each Pillar. Assign a numeric score (1–5) per pillar using the defined rubric. A score of 1 indicates a critical deficiency requiring immediate correction; 5 indicates full sustainment. Calculate the overall area score as the average of the five pillar scores.

4 Identify Non‑conformances & Red‑Tag Items. List every item that violates 5S principles (e.g., missing shadow boards, oily floors, broken tool holders). Attach a red tag to physical items and record the tag number, description, location, and discovery date in the red‑tag log.

5 Create Follow‑Up Action Plan. Prioritise all non‑conformances by severity and impact. For each item assign: a responsible person, a specific corrective action, and a target completion date. Enter all items into the action plan template. This plan becomes the primary driver for the next audit cycle.

6 Close the Audit Cycle. Present the scored results and the action plan to the area team during a brief stand‑up meeting. Update the area’s visual management board with the new score and action items. Schedule the re‑audit follow‑up date (typically within 2 weeks) to verify completion.

5S Audit Scoring And Follow Up Action Plan

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