What this checklist covers
The 5S Warehouse Checklist is a 15-point scorecard for storage layout, aisle marking, stock visibility, pallet condition, material flow, receiving and dispatch areas, and inventory housekeeping. Each criterion is scored from 1 to 5 on what the auditor sees on the day, and every gap goes into an action plan with an owner and a close date.
AutoSmart tip: Warehouse 5S audits should include a random location check — select five rack locations from the WMS or inventory system and physically verify that what is recorded matches what is present. A location accuracy below 95% is a strong indicator that housekeeping and put-away discipline are not being maintained consistently between cycle counts.
The checks
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Storage layout and aisle marking
- Is the warehouse storage layout documented in a current floor plan, with every zone and rack position labelled consistently against the plan?
- Are all main aisles and pedestrian walkways marked with clear floor tape or painted lines, with widths compliant with safe passage and forklift operation requirements?
- Are storage zones clearly defined and labelled — distinguishing receiving, active stock, slow- moving, returns, and dispatch areas without ambiguity?
- Are emergency exits, fire equipment positions, and first aid locations clearly marked and unobstructed throughout the warehouse?
Stock visibility and pallet condition
- Is stock visible and identifiable from the aisle without needing to enter the rack bay or move items, with labels facing outward and legible?
- Are pallets in good condition — free from broken boards, protruding nails, or structural damage — with damaged pallets removed from use and quarantined?
- Are pallets stacked at or below the maximum safe height for the rack system in use, with no overloading above the rack's rated capacity?
- Is stock placed squarely on pallets with no overhang that could create a falling hazard or obstruct visual identification?
Receiving and dispatch area
- Is the receiving area free from accumulation — with inbound goods processed and put away within the defined timeframe, not left in the receiving zone indefinitely?
- Is the dispatch area organised so outbound shipments are staged in a clearly designated zone, labelled, and ready for collection without obstructing other operations?
- Are receiving and dispatch records (goods received notes, delivery documentation) filed or entered into the system at the point of receipt/dispatch, not accumulated for batch processing?
Material flow and inventory housekeeping
- Is the material flow through the warehouse logical and unidirectional where possible — with inbound and outbound paths separated to avoid cross-traffic?
- Is a cycle count programme in place, with a defined percentage of warehouse locations counted each period rather than relying solely on annual stock takes?
- Are inventory discrepancies found during cycle counts investigated and resolved before the next count, rather than accepted as normal variance?
- Is a daily housekeeping routine in place for the warehouse, covering aisle clearing, equipment return, and refuse removal, with responsibility assigned to named individuals?
How to run it
How the scoring works
Before the visit, fill in the dealer or centre, the auditor, the date and the audit cycle. Then score each of the 15 checks from 1 to 5 on what you see on the day, not on what the site aims for, and add them up out of 75.
- 1Not in place
- 2Attempted
- 3Defined
- 4Managed
- 5Fully sustained
- Green60–75 · 80–100%Compliant. Keep the standard.
- Amber38–59 · 50–79%Improvement needed: a structured action plan within 30 days.
- Red0–37 · Below 50%Priority intervention, escalated to regional management.
Then close every gap
Each gap goes into the action plan tracker and moves through four stages until the auditor closes it.
- 1PendingOwner and close date set
- 2In progressWork under way, evidence gathered
- 3CompletedEvidence submitted for review
- 4ApprovedVerified and closed by the auditor
