Standard Work & 5S · Audit & Matrix Form
5S Lean Manufacturing Gemba Walk Master Audit Template
A comprehensive 5S audit template designed for Gemba walks. Evaluate work areas against the five pillars of visual workplace organization, assign scores, and drive kaizen based on real-time observations.
Frequency
Daily / Weekly
Department
Production / Shop Floor
Methodology
5S / Lean / Gemba
Version
2.1
Overview & Purpose
This master audit template standardizes the 5S evaluation process across all production areas. By conducting regular Gemba walks using this matrix, plant leadership can objectively score Sort (1S), Set in Order (2S), Shine (3S), Standardize (4S), and Sustain (5S) activities. The scoring system (1-5) highlights areas of strength and exposes gaps for immediate countermeasure deployment. Consistent use of this template builds a culture of visual discipline and continuous improvement.
Prerequisites & Context
- All area team members have completed foundational 5S training (Sort, Set, Shine) and understand the plant's visual management standards.
- Current area layout map (paper or digital) showing designated locations for all equipment, tools, and materials.
- Audit is conducted jointly with the area team lead or cell owner to ensure accurate context and immediate feedback loops.
- Previous audit scores and corrective action log should be available for review to track trend performance.
Audit / Evaluation Matrix
| 5S Pillar | Criteria / Metric | Evaluation Question / Standard | Score (1-5) | Notes / Observations |
|---|---|---|---|---|
| 1S · Sort (Seiri) | Red Tag / Hold Area Management | Does a designated red tag area exist? Are items in the area clearly tagged with date, origin, and justification? Are unneeded items removed from the active workspace? | [ ] | _________________________ |
| 1S · Sort (Seiri) | Essential Items Only | Are only the necessary tools, dies, fixtures, and materials present for the current production schedule? Are obsolete drawings or expired materials purged? | [ ] | _________________________ |
| 2S · Set in Order (Seiton) | Tool & Equipment Storage | Does every tool have a designated, clearly labeled home (shadow board, drawer insert, rack)? Are tools returned after use? Are walkways and material staging areas clearly marked? | [ ] | _________________________ |
| 2S · Set in Order (Seiton) | Visual Labels & Signage | Are all location labels, floor markings, and directional signs legible and correctly applied? Do location labels match the standardized naming convention? | [ ] | _________________________ |
| 3S · Shine (Seiso) | Daily Cleaning Schedule | Is a cleaning schedule clearly posted and adhered to? Are machines, floors, and work surfaces free of debris, oil, and dust? Are cleaning supplies readily accessible? | [ ] | _________________________ |
| 3S · Shine (Seiso) | Contamination Control | Are sources of contamination (leaks, dust, chips) identified and are countermeasures in place? Are inspection points clean and easy to access? | [ ] | _________________________ |
| 4S · Standardize (Seiketsu) | Visual Standards Posted | Are the 5S standards for this specific area posted (e.g., photos of the ideal condition, responsibility matrix)? Is there a standard method for cleaning and organizing? | [ ] | _________________________ |
| 4S · Standardize (Seiketsu) | Role Clarity & Accountability | Is the 5S responsibility matrix current? Does every team member understand their specific duties for maintaining organization and cleanliness? | [ ] | _________________________ |
| 5S · Sustain (Shitsuke) | Audit & Score Transparency | Are 5S audit scores prominently displayed on the area communication board? Are scores trending positive over the last 4-6 weeks? Are there documented corrective actions for low-scoring items? | [ ] | _________________________ |
| 5S · Sustain (Shitsuke) | Training & Discipline | Are all employees current on their 5S training? Is there a process for onboarding new hires and re-training when standards are not met? Are Gemba walks conducted with respect and focus on process, not blame? | [ ] | _________________________ |
Action Items & Follow-Up Plan
| Date | Gap Identified | Countermeasure / Action | Owner | Target Date |
|---|---|---|---|---|
| 2025-05-21 | Red tag area not utilized; holds obsolete tooling with no review date. | Re-train team on red tag criteria and schedule monthly review meeting with area lead. | Area Lead | 2025-05-30 |
| ___/___/_____ | _______________________________ | _______________________________ | _______ | ___/___/_____ |
| ___/___/_____ | _______________________________ | _______________________________ | _______ | ___/___/_____ |
| ___/___/_____ | _______________________________ | _______________________________ | _______ | ___/___/_____ |
| ___/___/_____ | _______________________________ | _______________________________ | _______ | ___/___/_____ |
Sign-Off & Verification
By signing below, the auditor, lean champion, or area supervisor verifies that all assessments have been completed accurately and improvement plans are communicated.
Auditor / Supervisor Signature
Date & Time