What this checklist covers
The 5S Workshop Checklist is a 15-point scorecard for tool arrangement, bay cleanliness, technician workstations, equipment placement, waste handling, floor markings, and safety zones. 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: 5S in the workshop is most effectively assessed mid-shift, not at the start or end of the day. A workshop that looks perfect at 8am and 5pm but is in disarray at 11am has a discipline problem, not a cleanliness problem — the standard exists only when the team has time to apply it, rather than being maintained as a working habit.
The checks
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Tool arrangement and bay cleanliness
- Are all tools in the workshop stored in a designated location — shadow board, tool chest drawer, or labelled rack — with no tools left on benches, floors, or vehicle surfaces when not in use?
- Is each workshop bay clean and free from oil spills, used rags, discarded parts, and packaging at the time of audit?
- Are tool storage areas organised so any missing tool is immediately visible without a physical count?
- Are broken or damaged tools removed from service, tagged, and placed in a designated repair or disposal area — not left in the active tool storage for another technician to unknowingly use?
Technician workstations and equipment
- Is each technician's workstation (tool chest, work bench) organised to the 5S standard, with personal items and non-work materials removed from the work area?
- Is workshop equipment (lifts, compressors, diagnostic tools) stored or parked in designated positions when not in use, not left blocking aisles or bays?
- Are consumables (rags, gloves, masking tape, oil absorbent) stocked at the point of use in defined quantities, with a replenishment trigger when stock reaches minimum level?
- Are PPE items (safety shoes, gloves, eye protection) available at the workstation, not stored elsewhere and fetched only when needed?
Waste handling and floor markings
- Are waste oil, used filters, and contaminated materials disposed of in the correct designated containers, with containers not overfilled?
- Are floor markings (bay boundaries, pedestrian walkways, equipment parking zones, hazard areas) clearly visible, undamaged, and accurate?
- Are aisles and walkways free from obstruction at all times, with no parts, tools, or equipment temporarily placed in walk routes? SAFETY ZONES & DAILY HOUSEKEEPING
- Are safety zones (around lifts, electrical panels, fire exits, first aid stations) clearly marked and unobstructed?
- Is a daily housekeeping routine in place for the workshop, with end-of-day cleaning and tool return completed before the last technician leaves?
- Are fire exits in the workshop clearly marked, unblocked, and confirmed functional?
- Is the 5S standard in the workshop maintained consistently throughout the working day, not only restored at end of shift before the next day?
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
