5S Audit Tool
Digital audit with AI-generated scoring, photo evidence log, and corrective action generation
22
/50
NEEDS WORK
Line 2 — Stamping Cell
SORT
3
/10 pts
SET IN ORDER
4
/10 pts
SHINE
5
/10 pts
STANDARDIZE
5
/10 pts
SUSTAIN
5
/10 pts
Unlabeled tooling bins — 14 items
No shadow board. Tools mixed with scrap parts in bin area near station 4.
SORT · HIGH
Die block stored in aisle — safety hazard
A-6 die block (220 lbs) staged in emergency egress path. OSHA violation risk.
SET IN ORDER · CRITICAL
Coolant residue buildup — 3 stations
Stations 2, 4, 7: coolant not cleaned between shifts. Slip hazard & die corrosion risk.
SHINE · MEDIUM
SOP-PRD-022 Rev 1.8 posted — outdated
Rev 2.2 issued June 8. Operators working from superseded procedure at station 4.
STANDARDIZE · MEDIUM
PLANTPILOT AI · 5S AUDIT SUMMARY
Score of 22/50 indicates systemic housekeeping breakdown, not isolated incidents. The aisle blockage (die block) is a immediate OSHA corrective action item — assign Rick Dolan before end of shift. The outdated SOP at station 4 is a direct IATF 16949 non-conformance. Sort and Set-in-Order failures at 3/10 and 4/10 indicate no visual management system is in place. Recommend a 5-day Kaizen event focused on shadow board installation, aisle marking, and visual control rollout before the next 5S audit cycle.
Root Cause Analysis — Fishbone (6M)
Problem: Line 2 scrap rate 3.1% — die clearance deviation at Station 4
👤 Man
Operator setup variation (no standard checklist)
No verification step for clearance setting
Shift changeover without tooling sign-off
⚙️ Machine
Tool AP-204 punch tip worn — 118K hits past PM
Die clearance deviation: 0.012" excess
Press ram alignment not verified at last PM
📦 Material
HSLA steel hardness variation batch-to-batch
2 incoming shipments not re-certified after supplier audit
Lubrication viscosity off-spec (SAP purchasing data)
📋 Method
SOP-PRD-022 outdated at station (Rev 1.8 vs 2.2)
No first-off inspection protocol for die change
PFMEA not updated for 2024 material change
📏 Measurement
Inline OEE sensor not calibrated Q1
Visual inspection only — no CMM at changeover
Scrap logging delay: 4-hr lag before supervisor notified
🏭 Environment
Line 2 ambient temp swings cause die expansion
Coolant residue buildup (5S issue) affecting die seating
Lighting at station 4 below OSHA lux requirement
PLANTPILOT AI · FISHBONE ANALYSIS
Primary root causes highlighted: Machine (Tool AP-204) and Method (SOP-PRD-022) categories contain the verified causal path. Man and Material factors are contributing — not root. Environmental factors (coolant / temp) explain residual 18% variance. Recommend 5-Why on the SAP PM record gap as the systemic enabler of the tooling failure.
5-Why Analysis
Problem: Tool AP-204 ran 118,000 hits past scheduled PM — root cause trace
1
WHY did Tool AP-204 run past its service interval?
The PM trigger was not issued in SAP — no work order was generated for the die PM.
2
WHY was no PM work order generated in SAP?
The tooling hit counter and PM schedule were not migrated during the SAP go-live in March.
3
WHY was the PM schedule not migrated to SAP?
The legacy die tracking spreadsheets were not included in the data migration scope — tooling PM was categorized as "low priority" data during project cutover planning.
4
WHY was tooling PM excluded from migration scope?
No cross-functional review between Maintenance, Engineering, and the SAP implementation team was conducted to verify all critical PM records were in scope.
5
WHY was no cross-functional review conducted?
SAP implementation was managed entirely by IT. No change management process required sign-off from Production and Maintenance stakeholders before cutover.
ROOT CAUSE — SYSTEMIC
SAP implementation lacked a cross-functional data migration verification process. IT change management excluded Production and Maintenance from go-live sign-off — allowing critical tooling PM records to be lost.
PLANTPILOT AI
The 5-Why reveals an organizational root cause, not a technical one. The SAP migration gap is a symptom of IT operating in isolation during a plant-critical system cutover. Corrective actions:
1. Immediate: Complete tooling PM record migration — R. Dolan + SAP PM (target June 28).
2. Short-term: Audit all SAP PM triggers against legacy records for all 3 production lines.
3. Systemic: Create an IT change management SOP requiring cross-functional sign-off before any plant system go-live. Document in IATF 16949 quality system.
1. Immediate: Complete tooling PM record migration — R. Dolan + SAP PM (target June 28).
2. Short-term: Audit all SAP PM triggers against legacy records for all 3 production lines.
3. Systemic: Create an IT change management SOP requiring cross-functional sign-off before any plant system go-live. Document in IATF 16949 quality system.