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Manufacturing

5S Audit Checklist

Sort, Set in Order, Shine, Standardise, Sustain — each scored on its own, so you can see which of the five is actually failing. Works on a shop floor, a dispatch bay or a back-of-house store.

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Audit Details

Which area, who assessed it, and against what.

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One area per audit. Averaging two areas into one score hides the worse one.

Carried forward. The direction of travel is the finding.

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1. Sort

Is anything here that does not need to be? Tidy is not the question.

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Walk the area asking one question of every object: does this need to be here to do today's work? Tidily stored things nobody will use again still fail Sort.

A red-tag area with a review date, rather than a corner things go to die in.

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2. Set in Order

One obvious place for everything. The test is a stranger finding it.

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The test for this section is not whether you can find things. It is whether somebody on their first day could, without asking.

Shadow boards, foam cutouts, outlined positions.

A Set in Order failure that is also a safety finding.

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3. Shine

Cleaning as inspection. Shine exists to reveal problems, not to look good.

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The point of Shine is not appearance. Cleaning a machine is how you find the leak, the crack and the loose fixing — so an area cleaned by someone who is not looking has not passed this section.

This is the check that separates Shine from mopping.

A Shine round that reveals nothing, repeatedly, usually means nobody is looking.

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4. Standardise

Is the right state written down, visible, and the same on every shift?

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Standardise asks whether "correct" is a matter of record or a matter of opinion. If two shifts would set this area up differently, it is not standardised.

The single most effective standardisation device there is.

Gauge markings, fill lines, colour coding.

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5. Sustain

Does it hold when nobody is auditing? The score that predicts the others.

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Score this section on evidence from between audits, not on what the area looks like right now. Everything in front of you was tidied because you were coming.

The moment that decides whether 5S survives is the first busy week.

An unannounced look, the audit history, what a team member says. Name it.

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Findings and Sign Off

Which of the five is failing, and what happens about it.

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Name it explicitly. It is the finding — the total is only the trend.

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5S is a method for organising a work area so that the right state is the easy state: Sort, Set in Order, Shine, Standardise, Sustain. This audit scores each of the five separately — on a shop floor, in a dispatch bay or in a back-of-house store — and you can fill it in here and download a finished PDF without creating an account.

What the five actually mean

The names are translations from the original Japanese and several of them are misleading in English. What each one actually asks:

  • Sort (seiri) — is anything here that does not need to be? Not "is it tidy". Tidily stored things you will never use again are a Sort failure.
  • Set in Order (seiton) — does everything have one place, and is that place obvious to a stranger? The test is whether a new starter can find it without asking.
  • Shine (seiso) — is it clean, and is the cleaning revealing problems? Shine exists to expose leaks, cracks and wear, not to look good.
  • Standardise (seiketsu) — is the right state written down and visible, so that "correct" is not a matter of opinion?
  • Sustain (shitsuke) — does it hold when nobody is auditing? This is the one that fails.

Why the five are scored separately

A single 5S percentage tells you almost nothing, because the same number can describe two completely different problems. An area scoring well on the first three and badly on the last two has been cleaned for the audit. An area scoring badly on the first two and well on the last three is sustaining a bad arrangement very reliably.

The first needs a system. The second needs a redesign. They look identical on a combined score, which is why this audit keeps them apart.

Sustain is the score that matters

Nearly every 5S programme that dies does so the same way: a strong launch, three good audits, then a gradual return to the previous state over about six months. The first four S's are events. Sustain is the only one that is a habit, and it is the only one that predicts whether the other four will still be true next quarter.

The scale here is written to make that judgeable. "Works when someone is watching" and "would survive the person who set it up leaving" are the two points people can actually tell apart, and the distance between them is the whole programme.

Photograph the standard, not just the mess

The most useful photograph in a 5S audit is the area when it is right. That photograph becomes the standard — it is what Standardise means in practice, and it settles arguments that a written description never will.

Speak while you walk, and the document the law or the client wants writes itself. Say what you are looking at as you score it, and the note that explains a 2 is attached to the 2 rather than reconstructed later from a camera roll.

Common questions

What does 5S stand for?

Sort, Set in Order, Shine, Standardise and Sustain — English renderings of seiri, seiton, seiso, seiketsu and shitsuke. Some organisations add a sixth S for Safety. This audit treats safety as something the other five should produce rather than a separate score.

How often should a 5S audit be done?

Monthly is the usual cycle once a programme is established, weekly during the first few months. The frequency matters less than whether the same person does it every time — consistency of judgement is what makes the trend readable.

What is a good 5S score?

Compare it to your own last one, not to anyone else's. Scoring is judgement, and two auditors will differ by ten or fifteen points on the same area. A rising trend from one assessor is meaningful; an absolute number across sites usually is not.

Is 5S only for factories?

No. It started on shop floors and works anywhere a physical area has a right state — dispatch bays, stockrooms, workshops, kitchens, laboratories, vehicle stores. This form is written to suit all of those rather than assuming a production line.

What is the difference between 5S and housekeeping?

Housekeeping is the third S on its own. 5S includes it but is mostly about the other four: removing what should not be there, giving everything one obvious place, writing the standard down, and building the habit. An area can be spotless and still fail a 5S audit badly.