Try it while you read
Open the free 5S Audit tool and click Load sample: it reproduces the case study below.
Theory: the five S and what each one means
| S | Goal | What the auditor looks for |
|---|---|---|
| Sort (Seiri) | Only what is needed is in the area | No unneeded tools, material, documents; red-tag area used and emptied |
| Set in order (Seiton) | A place for everything, everything in its place | Marked locations, labels, shadow boards, aisles and safety equipment free |
| Shine (Seiso) | Clean, and cleaning is inspection | Clean machines and floor, sources of dirt (leaks, chips) known and being removed |
| Standardize (Seiketsu) | The first three S are the normal state | Visual standards, photos of the target state, responsibilities displayed |
| Sustain (Shitsuke) | It stays that way without campaigns | Regular self-checks recorded, findings closed, management walks the area |
Scoring 0 to 4
Each question is rated on a maturity scale: 0 not done, 1 just started, 2 partly in place with clear gaps, 3 mostly in place, 4 fully in place and sustained. The score of an S is its points in percent of the maximum, and the overall score is the mean of all rated questions. Questions that do not apply are left out, so a small area is not punished for missing equipment.
Key point
Step by step
- Choose the area and invite the team leader and an operator of the area to walk with you.
- Open the 5S audit, enter area, auditor and date, and adapt the questions with Edit checklist if your area needs other ones.
- Rate every question 0 to 4 on the spot. For 2 or less the finding, action, owner and due date fields open; add a photo.
- Read the result: overall score, score per S and the list of findings.
- Agree the actions with the team before you leave the area, then download the PDF report.
- Repeat monthly and compare: the trend shows whether the area sustains.
Case study: machining area, monthly cross audit
A supervisor from assembly audits the CNC area with its team leader (the Load sample data). All 26 applicable questions are rated.
| S | Score | Findings (≤ 2) |
|---|---|---|
| Sort | 90 % | 0 |
| Set in order | 75 % | 2 |
| Shine | 80 % | 1 |
| Standardize | 85 % | 0 |
| Sustain | 80 % | 1 |
| Overall | 81.7 % | 4 |
The four findings: the aisle marking in front of the electrical panel is worn (S8), gauges are stored loose in a drawer (S10), the coolant leak at machine 2 is known but not repaired (S15), and the team’s weekly self-check was skipped for three weeks (S22). Set in order is the weakest S, and two of its findings are quick fixes: repaint the marking and add a foam insert for the gauges.
Result
Common mistakes
- 5S as a cleaning campaign before a customer visit, then nothing until the next one.
- Auditing an area without the people who work there, so the findings are not accepted.
- Scoring plans and intentions instead of the current state.
- Findings without owner and date, or findings that are never checked at the next audit.
- Ignoring the sources of dirt and cleaning the same leak every day.
For daily confirmation that the standard holds, combine the monthly 5S audit with short layered process audits.
Frequently asked questions
What is a good 5S score?
There is no universal limit. Many plants treat 80 % as the level where an area is stable and 90 % as best practice. The trend and the weakest S matter more than the number: an area at 85 % with Sustain at 60 % will slide back.
How often should a 5S audit be done?
A short self-check by the team weekly and a cross audit by another area or the supervisor monthly. Layered process audits can include a few 5S questions so it is checked every day.
Is 5S required by IATF 16949?
Not by name, but clause 7.1.4 asks for a work environment that supports conformity, and many customer-specific requirements and audits (for example VDA 6.3, P6.4) look at order, cleanliness and storage on the shop floor.