TITLE: DOC. No.

: FO A Q 011

Revision History & Distribution DATE: 30th Sep 2008

DEPARTMENT: CLASSIFICATION:

DCC - Quality Assurance Form

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

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

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

APC MGE logo changed to APC by Schneider Electric & in reference procedure number
E 06th May 2009
has been added. Department Name has been changed to IRC / Production

Whole Check List template has been Modified & modified with adding different
F 25th Aug 2009
Workshop daily, Office Daily, Committes for workshop & office

15days Date Column has been added to save Paper Cost & added one Sheet known as
G 03rd Sep 2009
CA-PA

H 26th Oct 2009 In 7s Office committee check list Point no. 24 & 25 has been repeated. Hence revised
 Distribution List
Department No Of Copies

Mfg Technology
Facility
Human Resources
Production
NPD
Purchase
Quality
Plat Form
Test Engineering
Warehouse
Opex
IT
Employees Service
 FO A Q 011 REV NO. C

: 30th Sep 2008 PAGE 1 of 1

REFERENCE:

Form PR A Q 010

E AUDIT CHECKLIST

Initiated By Approved By

Cell Trainers
-

Arun kumar Raju

-

Arun kumar Raju

-

Cell Trainers
-

ference procedure number

Sumana Sundara Rajulu
C / Production

with adding different Suman Dev & Ashish &

ce Jaykanth Devdas

added one Sheet known as

Ganesh Jaykanth Devdas

Ashish &
n repeated. Hence revised Suman
Devdas
Special Instruction

Soft Copy controlling

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

7s Workshop Daily/Weekly/fortnightly DATE: 26th Oct 2009 PAGE 1 OF 2

DEPARTMENT: Warehouse CLASSIFICATION: REFERENCES:
All CHECKLIST PR A P 027
Sheet No. 1 Cell

Factory Stage Audited by & ID No

Sector Shift Date of Auditing
7S Sl No Description 10-Mar 11-Mar 12-Mar 13-Mar 14-Mar 15-Mar 16-Mar 17-Mar 18-Mar 19-Mar 20-Mar 21-Mar 22-Mar 23-Mar 24-Mar 25-Mar

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

Work tools are available and identified and stored in proper area. All PPEs/Work instructions are kept in
2
properly 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 unidentified
3
Straighten

objects 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 etc
4
under 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
5
,equipments stored are in USABLE condition
Shine

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

All the equipment ,parts ,work bench etc in the area are clean and usable (no abnormality like
7
loose,open,leaking,come out ,open holes)

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

Do all the racks/storage bins/work bench/furniture/instructions /files/file numbering and storage /display
9
systems look same at different cell/sectors

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

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

The 7S KPI's are updated and managed in SIM.All the employees know the 7S concept and score of more
12
than 90% for more than 6 months.

13 SIM is implemented and respected.

Safety protections are used, are in good condition and ESD certified ,ESD and equipment safety checklists
14
available and completed. No safety interlock is bypassed

Free passage, no carton, trolleys/racks and no pallets on the pathways. The pathways and storage is clearly
15
marked and safety equipment are not blocked.

Safety & Ergonomic precautions for each stage identified and visually depicted, exit routes are clearly
Safety

16
marked 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
17
authority .

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

There is no spillage /overflow of material or scrap on the ground or on the workstation, waste material is
19
Save Earth

collected every hour

There is no emission of harmful gases or chemicals in the work area, waste material is segregated at source
20
(Plastic,Metal,heavy metals etc)

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

7s Office Daily/Weekly/fortnightly DATE: 26th Oct 2009 PAGE 1 OF 2

DEPARTMENT: CLASSIFICATION: REFERENCES:
All CHECKLIST PR A P 027
Sheet No. 2 Cell

Factory Stage Audited by & ID No

Sector Shift Date of Auditing
7S Sl No Description

Area is clean, no item on on the window ledges, empty bins ,under the tables ,on the floor. No broken
1
/damaged furniture .
Sort

No junk drawer or cupboard in the area ,no junk papers ,notices obsolete documents ,no broken or
2
obsolete 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, no
3
double markers/stapler/punching machines etc

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

5 Common areas ,aisles are identified with clear responsibility

6 All shelves ,drawers are properly identified with responsibility known

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

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

Respect of identification system for documents and files. Proper 7 S is maintained for the files and
9
Standardize

documents and documentation rules are standard.

All the common and personal cupboards and drawers identified ,objects can be found without opening the
10
drawer/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
11
notice boards are standard ,telephone/computer places are marked
Sustain

7S activity is done as per standard check list every day ,7 S scores are displayed and 7 S is part of daily
12
diary and SIM events

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

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

ERT persons identified in the office area ,Emergency exits clearly marked and evacuation route is visual.
Safety

15
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 safety
16
manual.

All the people are aware of the environmental impacts of the processes, people show their awareness by
17
Save Earth

reducing electricity/water consumption etc.

Classification of hazardous/non hazardous waste available and procedure of clearing the wastes and
18
sanitation is effectively done

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
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
Score Scoring Guidelines
0 No Concept of 7s
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
 TITLE: DOC NO. CH A P 023 REV NO. H
7s Workshop Daily/Weekly/fortnightly DATE: 26th Oct 2009 PAGE 2 OF 2
DEPARTMENT: CLASSIFICATION: REFERENCES:
All CHECKLIST PR A P 027

Date Non conformance CA / PA Closure date Date Non conformance CA / PA Closure date
 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. 3 Sector Date of Audit

Cell Stage Audited By & ID No

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

1 Only the required spare parts, materials, WIP(in MPH (> 2 pitch
time), etc. are present at the workstation. Items not required to
make the current product are removed from the workplace.(Check
for hidden areas also ie under work stations,behind pillars

Only the required tools are present at the workstation. Items not
2 required to make the current product/or carry out the current job are
removed from the workplace.

Only the required paperwork(files /documents/information is

Sort

3 present at the workstation. Out-dated or otherwise unnecessary

posters, memos, announcements, reports, etc. are removed from
the workplace.

Only the required equipment is present at the workstation. All

4 obsolete, broken or unnecessary equipment, shelves, lockers,
workbenches, etc. not required to make the current product is
removed from the workplace.

Only the required furniture is present at the workstation. All

broken or unnecessary chairs, shelves, lockers, workbenches, etc.
5 not required to make the current product is removed from the
workplace.(also check for broken window panes ,damaged
mats,damag

Work cells are clearly defined ,Locations for containers,

6 boxes, bins, WIP, materials,wastes etc. is clearly defined by
painted 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 the

7 operator for that stage based on frequency of use (Daily tools near
operator in tool shadow box). The location is properly labeled and
tools can easily be identified if absent.
Set in Order

Paperwork ( WI's and communication boards ) is properly

8 labeled and has a clearly defined and labeled location that is visible
to the operators and away from work surfaces.

Equipment is clearly identified (numbered, named, color coded,

9 etc.) and placed in a properly identified location. Critical
maintenance points and critical parameters are clearly marked. (On
the machine /available near the machine)Equipments like trolleys
Furniture is clearly identified (numbered, named, color coded, etc.)
10 and placed in a properly identified location. (Furniture includes
bins,racks,cleanining items etc)

11 Containers, boxes, bins, etc. are clean and not cracked, torn, or
otherwise damaged. They are neatly stacked.
Tools are kept clean and in good working order. Where possible,
12 tools are stored in a manner to keep them clean and free from risk of
damage.
13 Paperwork is not torn, kept clean and protected from dirt.
Work surfaces (machines, workbenches, dies, and other
14 equipment including electrical boxes) are clean and painted and are
in good condition.
Shine

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

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

17 There is a schedule showing times, frequency and responsibilities

to clean areas of the workplace such as windows, corners, walls,
doors, top of cabinets, etc.

18 All cleaning equipment is neatly stored and is readily available

when needed.

19 Tools, equipment, paperwork, furniture, etc. are stored neatly

in designated areas and are returned immediately after each use.

Documents are labeled clearly as to contents and responsibility for

20 control and revision. The date and revision number are clearly
Standardize

visible. The document storage is standardized in all areas including

support functions.
Equipment maintenance records are visible and clearly state
21 when maintenance last occurred and when next maintenance is
scheduled.

22 The results of the previous audit are posted and clearly visible to
the entire team.
Standardize

23 Areas for improvement identified during the previous audit have

been completed.
 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:
All CHECKLIST PR A P 027

24 Daily assessments realised by operators

Monthly audits realised by management staff

25 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. designated
26
Sustain

daily/weekly clean-up time, 5S team leader, etc.)

27 All operators, team leaders, supervisors, etc. are assigned

5S activities to be completed at least once/week

5S is managed in SIM: indicators, suggestions, action plan

28 5S Methodology is encouraged and valorized The team takes the
initiative to make improvements to the workplace that were not
identified during the last 5S audit.
Tripping dangers such as electrical cables, obstructions to
29 movement ,pipes ,hanging wires and hoses etc. are removed from
standing/walking areas.

30 Work areas requiring personal protective equipment are clearly

labeled and place of keeping PPE is defined.
Stop switches and breakers are highly visible and located for
31 easy access in case of emergency.In no case they are covered and
located at inaccessible areas.Panels/doors of switchgears cable
entries are secured as per standards.

32 Fire hoses, fire extinguishers and other emergency equipment

are prominently displayed and are unobstructed.
Working conditions are ergonomically friendly. Tools are stored
Safety

33 at appropriate heights, lift assist devices are provided where

necessary, etc.

34 The workplace layout accomodates easy exit in case of

emergency.(Evacuation route is not complicated /Zigzag )

35 Walkways and vehicle paths are clearly identified and

unobstructed. Exits are clearly labeled and unobstructed.

All personal protective equipment is maintained in sanitary and

36 reliable condition and is properly stored in a easily accessible and
labeled location when not in use. The First aid box and emergency
cupboards are available in proper form.
Equipment safety concerns are clearly identified. Safety guards
37 are painted, in good working condition and provide adequate
protection.

Product waste (e.g. shavings, containers, liquids, wrappers, etc.) is

38 consistently and often cleaned up and removed from the
workplace.Including other wastes like dross /Acids /CFC etc which
are not environment friendly show a reducing consumption level.
Save Earth

Preventive measures have been implemented based on root

39 cause analysis of the problems found during daily audits to ensure
the workplace meets 5S guidelines (e.g. systems that do not allow
waste to accumulate such as containers to collect product debris
The work environment satisfies the requirements of the work being
40 performed. Lighting (brightness and color), air quality, temperature,
etc.
TOTAL

Score

Score Calculation Formula = (Total/40)/5*100. 40 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

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

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

DEPARTMENT: CLASSIFICATION: REFERENCES:
All CHECKLIST PR A P 027

Sheet No. 4 Sector Date of Audit

Cell Stage Audited By & ID No

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

There are no unnecessary office furniture or equipment,

1 substucture, office furniture and equipment are in good condition
Space is optimized (dimension of areas, lay-out …)

There are no unnecessary equipments or supplies: equipments and

2 furniture are in good condition
Mutual cupboards / Mutual files are optimized (surface / volume )
Sort

There are no unnecessary items (peripheral, supplies, tested

3 parts ...: personnal objects for decor are accepted but limited
There are no personnal equipment redundant with mutual one

There are no unnecessary information or documents: documents

4 and files are in good condition
There are no personnal files redundant with mutual one
Different areas (aisles -work spaces...) are defined (marqued if
5 possible) and set in order
Office is identified and people are located on the area

Equipments, files, furniture are appropriately located: easy to find,

Set in Order

6 easy to place: locations are identified and arranged per layout

Specific cleaning equipment is arranged per layout

Files, furniture, equipements and accessories (test parts for ex…)

7 are appropriately located
In absence the setup desk is free of document or file

Documents and files are identified and appropriately located

8 Information boards are set in order: visual, easy to understand

The floor is clean and maintained continuously

9 Walls, windows, ceilings, substructure... are clean and inspected
periodically

Clean and Preventive Maintenance (if appicable) is organized and

Shine

10 respected
Cleaning is facilitated (no cable on the floor, display cabinets …)
Desk, cupboards, equipments are clean and maintenened: trash is
11 sorted
Cleaning tools are adapted and optimized
12 Information board, documents , files are clean and maintened
Safety rules / Evacuation plan are updated and applied
13 5S standard is known and respected: VISUAL

Visual management is in place: anyone can distinguish normal and

Standardize

14 annormal

SIM standards(event cycle, staff diaries management …) are known

15 and applied

Communication board / SIM board are updated and visual

16 Performance indicators on Department are managed and updated

Each employee (including temporary workers) is trained, respected

17 rules and is involved in continuous improvement

Daily / Weekly assessments realised by team

18 Monthly audits realised by management staff
Sustain

SIM is respected and continuously improved: action plan , diary

19 management, SIM meetings, red green analysis … are respected

5S is managed in SIM meetings: Indicatorrs, Suggestions, Action

20 plan
5S Methodology is encouraged and valorized

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

ERT persons identified in the office area ,Emergency exits clearly

Safety

22 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

23 and visual. All Departments have safety manual.

All the people are aware of the environmental impacts of the

24 processes, people show their awareness by reducing
Save Earth

electricity/water consumption etc.

Classification of hazardous/non hazardous waste available and

25 procedure of clearing the wastes and sanitation is effectively done

TOTAL

Score

Score Calculation Formula = (Total/27)/5*100. 27 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

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 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