Facility Review Checklist
Manufacturing
Mgt Review of Manufacturing Sites
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Audit

FACILITY

SAFETY & ENVIRONMENT

WORK ENVIRONMENT

Is the general working environment in a safe & health condition for operators?
OK
LOW
MIN
MAJ
HIGH
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NO spilled hazardous materials or liquids?
OK
LOW
MIN
MAJ
HIGH
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Combustible scrap, debris & waste stored safely and removed?
OK
LOW
MIN
MAJ
HIGH
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Work areas adequately illuminated?
OK
LOW
MIN
MAJ
HIGH
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MACHINE GUARDING

Is machinery being operated properly guarded / secured to prevent injuries to operators?
OK
LOW
MIN
MAJ
HIGH
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Power shut-off switch within reach of the operator's position?
OK
LOW
MIN
MAJ
HIGH
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Foot-operated switches guarded to prevent accidental actuation?
OK
LOW
MIN
MAJ
HIGH
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Emergency stop buttons colored red and working?
OK
LOW
MIN
MAJ
HIGH
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Moving chains and gears properly guarded?
OK
LOW
MIN
MAJ
HIGH
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HAZARDOUS CHEMICAL EXPOSURE

Is the operator not exposed to, or adhering to safe working practices in terms of chemical exposure?
OK
LOW
MIN
MAJ
HIGH
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Eye wash fountains and safety showers provided?
OK
LOW
MIN
MAJ
HIGH
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All containers, such as vats, storage tanks, etc., labeled?
OK
LOW
MIN
MAJ
HIGH
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All staff are using relevant PPE and have clean uniforms. Personal protective clothing and equipment Std?
OK
LOW
MIN
MAJ
HIGH
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No eating in the workplace?
OK
LOW
MIN
MAJ
HIGH
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OPERATOR SAFETY

Is the operators protected against the necessary safety risks in the work place?
OK
LOW
MIN
MAJ
HIGH
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Floor & Wall Openings: floor openings guarded?
OK
LOW
MIN
MAJ
HIGH
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Forklifts / Vehicles: warning horn, trained personnel?
OK
LOW
MIN
MAJ
HIGH
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Noise: hearing protective equipment?
OK
LOW
MIN
MAJ
HIGH
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Spray Machines: adequate ventilation?
OK
LOW
MIN
MAJ
HIGH
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Aisles & Passage Ways: aisles and passageways kept clear, marked as appropriate, wet surfaces covered with non-slip materials?
OK
LOW
MIN
MAJ
HIGH
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LOCKOUT/TAGOUT

Is all machinery or equipment blocked or locked-out during cleaning, servicing, adjusting or setting up operation, whenever required?
OK
LOW
MIN
MAJ
HIGH
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Lock Out Tag available / not accessible?
OK
LOW
MIN
MAJ
HIGH
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Safe job procedure established and rigidly followed?
OK
LOW
MIN
MAJ
HIGH
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WORK PLACE ORGANIZATION (5S)

SORT / ORGANIZATION

Is the workplace well organized?
OK
LOW
MIN
MAJ
HIGH
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Unneeded equipment, tools, furniture, etc. are present?
OK
LOW
MIN
MAJ
HIGH
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Unneeded items are on walls, bulletin boards?
OK
LOW
MIN
MAJ
HIGH
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Items are present in aisle ways, stairways, corners?
OK
LOW
MIN
MAJ
HIGH
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Unneeded inventory, supplies, parts, or materials are present?
OK
LOW
MIN
MAJ
HIGH
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Safety hazards ( water, oil, chemicals, machines ) exist?
OK
LOW
MIN
MAJ
HIGH
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SET IN ORDER / ORDERLINESS

Are all work areas maintained in a state of order?
OK
LOW
MIN
MAJ
HIGH
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Correct places for items are not obvious, Items are not in there correct places?
OK
LOW
MIN
MAJ
HIGH
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Aisle ways, workstations, equipment locations are not indicated?
OK
LOW
MIN
MAJ
HIGH
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Items are not put away immediately after use?
OK
LOW
MIN
MAJ
HIGH
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Height and quantity limits are not obvious?
OK
LOW
MIN
MAJ
HIGH
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SHINE / CLEANLINESS

Are all work areas maintained in a state of cleanliness?
OK
LOW
MIN
MAJ
HIGH
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Cleaning, and looking for ways to keep it clean and organized?
OK
LOW
MIN
MAJ
HIGH
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Floors, walls, stairs, and surfaces are not free of dirt, oil and grease?
OK
LOW
MIN
MAJ
HIGH
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Equipment is not kept clean and free of dirt, oil, and grease?
OK
LOW
MIN
MAJ
HIGH
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Cleaning materials are not easily accessible?
OK
LOW
MIN
MAJ
HIGH
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Lines, labels, signs, etc. are not clean and unbroken?
OK
LOW
MIN
MAJ
HIGH
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Other cleaning problems ( of any kind ) are present?
OK
LOW
MIN
MAJ
HIGH
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STANDARDIZE / ADHERENCE

Is the necessary work standards, visual aids available, and adhered to?
OK
LOW
MIN
MAJ
HIGH
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Maintain the workplace as per standard visual aids?
OK
LOW
MIN
MAJ
HIGH
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Necessary information is not available, All standards are not known and visible?
OK
LOW
MIN
MAJ
HIGH
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Checklists don't exist for all cleaning and maintenance jobs?
OK
LOW
MIN
MAJ
HIGH
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All quantities and limits are not easily recognizable, How many items can't be located in 30 seconds?
OK
LOW
MIN
MAJ
HIGH
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PROCESS CONTROL / FPF

DOCUMENTATION / TOOLS

Is the necessary documentation and standards available?
OK
LOW
MIN
MAJ
HIGH
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Process / FPF Manual available and up to date?
OK
LOW
MIN
MAJ
HIGH
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Visual Aids available and current?
OK
LOW
MIN
MAJ
HIGH
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Gauges and Tools available & calibrated?
OK
LOW
MIN
MAJ
HIGH
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Forms for FPF Available & Legible?
OK
LOW
MIN
MAJ
HIGH
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SETUP / 1ST PIECE APPROVAL

Is the start of shift setup and 1st piece approval carried out?
OK
LOW
MIN
MAJ
HIGH
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All Machine Check Points Completed prior to start of 1st run?
OK
LOW
MIN
MAJ
HIGH
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All Process & Product Points Completed prior to start of run & Signed?
OK
LOW
MIN
MAJ
HIGH
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First Piece Approval part available and stamped correctly.
OK
LOW
MIN
MAJ
HIGH
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PROCESS CONTROL

Is the process in control against the set standards, or process parameters?
OK
LOW
MIN
MAJ
HIGH
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Process setup as per Process/work order / WI?
OK
LOW
MIN
MAJ
HIGH
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Process/work order signed and updated?
OK
LOW
MIN
MAJ
HIGH
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SPC Charts updated and actions taken on deviations, FPF Documents updated and signed
OK
LOW
MIN
MAJ
HIGH
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PROCESS MONITORING / PERFORMANCE

Is the FPF Performance monitored, at regular intervals?
OK
LOW
MIN
MAJ
HIGH
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Process Performance Boards maintained, all required information posted on Boards?
OK
LOW
MIN
MAJ
HIGH
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PROCESS VALIDATION

Is the FPF 5P Audit carried out and actioned?)
OK
LOW
MIN
MAJ
HIGH
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FPF Audit Checklist completed and current?
OK
LOW
MIN
MAJ
HIGH
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FPF Performance Chart updated?
OK
LOW
MIN
MAJ
HIGH
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Non conformance communicated and actioned, Escalation of failures (if needed)
OK
LOW
MIN
MAJ
HIGH
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CUSTOMER ISSUES & ACTIONS

Are operators aware of customer complaints and is actions taken?
OK
LOW
MIN
MAJ
HIGH
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Quality Alert posted and Current?
OK
LOW
MIN
MAJ
HIGH
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Customer Reject Samples available?
OK
LOW
MIN
MAJ
HIGH
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Actions taken based on corrective actions documented?
OK
LOW
MIN
MAJ
HIGH
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STANDARDIZED WORK

WORK STANDARD

Is the work standard available with the necessary information?
OK
LOW
MIN
MAJ
HIGH
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Cycle Time?
OK
LOW
MIN
MAJ
HIGH
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Machine Layout?
OK
LOW
MIN
MAJ
HIGH
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Order of Operations?
OK
LOW
MIN
MAJ
HIGH
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Work Sequence for the operator (visual)?
OK
LOW
MIN
MAJ
HIGH
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Quality Checks?
OK
LOW
MIN
MAJ
HIGH
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Safety Precautions?
OK
LOW
MIN
MAJ
HIGH
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Trained operator?
OK
LOW
MIN
MAJ
HIGH
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WORK SEQUENCE

Is the operator conducting the work as stipulated in the STD Work instruction?
OK
LOW
MIN
MAJ
HIGH
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Work activity / sequence against std instruction?
OK
LOW
MIN
MAJ
HIGH
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Devices / Tools / Machinery used correctly?
OK
LOW
MIN
MAJ
HIGH
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Continuous Flow of product?
OK
LOW
MIN
MAJ
HIGH
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Cycle Time is kept to the standard (check SWI)?
OK
LOW
MIN
MAJ
HIGH
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STANDARD WIP

Is there any material WIP, or visible material flow issues?
OK
LOW
MIN
MAJ
HIGH
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Imbalanced parts or unfinished work pieces?
OK
LOW
MIN
MAJ
HIGH
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Excessive WIP / Material before and after process?
OK
LOW
MIN
MAJ
HIGH
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Next process waiting for material?
OK
LOW
MIN
MAJ
HIGH
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WASTE MANAGEMENT

Is there any evidence of 7 wastes and action taken to correct?
OK
LOW
MIN
MAJ
HIGH
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Transportation (moving products that is not actually required to perform the processing)?
OK
LOW
MIN
MAJ
HIGH
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Inventory (all components, work-in-progress and finished product not being processed)?
OK
LOW
MIN
MAJ
HIGH
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Motion (people or equipment moving or walking more than is required to perform the processing)?
OK
LOW
MIN
MAJ
HIGH
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Waiting (waiting for the next production step)?
OK
LOW
MIN
MAJ
HIGH
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Overproduction (production ahead of demand)?
OK
LOW
MIN
MAJ
HIGH
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Over Processing (due to poor tool or product design creating activity)?
OK
LOW
MIN
MAJ
HIGH
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Defects (the effort involved in inspecting for and fixing defects)?
OK
LOW
MIN
MAJ
HIGH
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OPERATIONAL PERFORMANCE

Is the performance tracked, maintained and action taken on deviations?
OK
LOW
MIN
MAJ
HIGH
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Performance standards established and known, Downtime sheets, Hourly output sheets, and tracking?
OK
LOW
MIN
MAJ
HIGH
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Actual performance in line with targets Internal PPM, FPF%, Productivity?
OK
LOW
MIN
MAJ
HIGH
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Close-Out

ACTION DECK

Action
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By Whom
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By When
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Action
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Action
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Action
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SIGNATURES

Signature

Auditor / Assessor
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Signature

Add signature
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