Warehouse Customer Audit Pre-Visit Walk

Pre-visit warehouse audit checklist to verify 5S readiness, documentation, training, and product condition before a customer audit.

5S and Housekeeping

• Aisles, exits, and access paths are clear and unobstructed
  Main aisles, emergency exits, dock paths, and access to panels, extinguishers, and eyewash stations are free of stored materials, pallets, carts, and debris.
• Floors are clean and free of spills, trash, and loose packaging
  No visible spills, standing liquids, loose stretch wrap, banding, broken pallets, or trash in active work areas.
• Tools, equipment, and materials are stored in designated locations
  Frequently used items are returned to labeled locations; no mixed storage or temporary clutter is present in work areas.
• Labels, signs, and floor markings are visible and legible
  Rack labels, bay locations, pedestrian markings, hazard signs, and customer-facing signage are intact, visible, and not obscured.
• Waste, recycling, and scrap containers are not overflowing
  Trash, cardboard, stretch wrap, and scrap are contained and removed before overflow creates housekeeping or fire-load concerns.
• 5S audit board or visual management board is current
  If used, the board shows current metrics, action items, ownership, and due dates with no outdated or missing information.

Documentation Readiness

• Current SOPs and work instructions are available at point of use
  Relevant procedures for receiving, put-away, picking, packing, shipping, returns, and exception handling are accessible and current.
• Training matrix is current for warehouse associates and leads
  Training records show current status for required tasks, equipment, safety, and customer-specific requirements.
• Inspection logs and maintenance records are complete
  Forklift, dock equipment, fire extinguisher, and other required inspection logs are complete, signed, and within required intervals.
• Customer-specific requirements and audit agenda are available
  Any customer scorecards, packaging rules, labeling requirements, or site-specific expectations are printed or accessible to the audit team.
• Corrective actions from prior audits are closed or have approved due dates
  Open findings are tracked with owners, due dates, and evidence of progress; overdue items are escalated.

Training and Competency

• Operators are trained and authorized for assigned equipment
  Forklift, pallet jack, dock equipment, and other powered industrial truck operators are current on authorization and training.
• Employees can explain emergency and evacuation procedures
  Sampled employees can identify alarm response, evacuation routes, muster points, and reporting expectations.
• PPE requirements are understood and followed
  Observed personnel are wearing the required PPE for the area and can state when additional PPE is required.
• Lockout-tagout awareness is demonstrated where applicable
  Maintenance or support personnel can identify when lockout-tagout applies and know who is authorized to perform it.
• New hire and refresher training gaps are identified
  Any overdue training, expired certifications, or unassigned training items are documented before the customer visit.

Product Condition and Storage

• Product and packaging are free from visible damage
  No crushed cartons, torn wrap, broken pallets, leaks, contamination, or other visible product defects are present in audit-visible areas.
• Inventory is properly labeled and traceable
  Pallets, bins, and locations have correct item identification, lot/serial information where required, and status labels are legible.
• Storage height and rack loading are within safe limits
  Stored product does not exceed rack capacity, block stacking limits, or safe clearances; damaged rack components are not in use.
• Quarantine, hold, and nonconforming product are segregated
  Rejected, damaged, expired, or customer-hold material is clearly identified and physically separated from good inventory.
• Temperature- or condition-sensitive product is within required limits
  If applicable, product storage conditions are within documented requirements and any excursions are recorded.

Safety and Fire-Life-Safety

• Emergency exits, egress routes, and exit signs are unobstructed and visible
  Exit access is clear, exit signs are illuminated or visible, and doors are not blocked, chained, or propped in a way that prevents egress.
• Fire extinguishers are mounted, accessible, and in inspection date
  Extinguishers are located correctly, unobstructed, and show current inspection status with no visible damage or missing tags.
• Housekeeping does not create a fire load or ignition hazard
  Accumulated cardboard, shrink wrap, dust, and combustible waste are controlled and not stored near heat sources or electrical equipment.

Audit Walk Closeout

• Overall readiness status
  Select the current readiness status after completing the walk.
• Top deficiencies and corrective actions
  Summarize the most important gaps, owners, and due dates before the audit begins.
• Inspector signature
  Signature of the person completing the pre-visit walk.