RED BIN
LOCK AND KEY RED BIN
MOSTLY PREFERED IN
INDUSTRY
Why we do RED BIN ?
Because in Red bin analysis we caught daily rejection and found root cause
immediately to solve the problem.
Red bin is a monitoring tool on monthly PPM. When problem have action
taken on daily basis, so it is easy to monitoring PPM and action is
implemented urgently.
Overall red bin analysis is a key to reduce our rejection, by taking action
on it.
Where Red bin is implemented ?
On all shop floor, Lines, section, zone or as per convenience.
What is Frequency of Red Bin Analysis ?
End of every shift.
Daily basis
Generally Red bin analysis is done on daily basis, with a fixed time at red
bin area. Because in Night shift managerial post member is not present so
it is not convenient to do shift wise.
Note :- Red bin meeting is not done on weekly basis.
Steps to be followed for RED BIN ANALYSIS
1. All members of the RED BIN team to meet at defined time to
discuss previous day rejection.
2. All members to daily sign the attendance sheet.
3. Disposition action : Review the defective parts if those can be
reworked, repaired or to be scrapped.
4. Daily Red bin Trend ,Analysis & countermeasure taken daily with
effectiveness monitoring
Criteria-(Action taken for equal to is grater than 2 pcs (As per
Requirement) rejected in a day at any line/machine And critical to cost
,critical to quality ,critical to Customer ) and set rejection target example
less 10% rejection from last month rejection.
Note :- Daily rejection is monitored from rejection report which have
made by line quality inspector and final inspection incharge.
After disposition action taken Rejected part to be note down in scrap note.
and Rework / Repair part to be note down in Rework / repair sheet.
After scrap note completed move the rejected material in scrap area on
daily basis, and Rework / repair material to Rework / Repair area.
5. Monthly defect pareto chart from PPM
DEFECT DEFECT CUMMELATI PERCENTAG
NAME QTY VE E
DENT 15 15 30.00
SCRATCH 10 25 50.00
O.D LINE 9 34 68.00
I.D LINE 7 41 82.00
CRACK 6 47 94.00
BURR 2 49 98.00
BEND 1 50 100.00
50
16 100.00 100.00
15 98.00
94.00
90.00
14
82.00
80.00
12
68.00 70.00
10
10
9 60.00
8 50.00 50.00
7
6 40.00
6
30.00 30.00
4
20.00
2
2
1 10.00
0 0.00
DENT SCRATCH O.D LINE I.D LINE CRACK BURR BEND
6. As per pareto chart action taken on Top 3 Defects or as per your
company SOP.
7. As per pareto chart Effectiveness monitoring on Top 3 Defects or
as per your company SOP.
8. Display Rejection sheet on Board
FMT:-F/AQE/23
AQE Training & HR Consultancy
Rev.No:-"00
MEMBERS OF RED BIN TEAM Eff.Date:-01/01/19
Sr.No Member Name Department Designation Sign
1 Mr.R.K Choudhary Overall Plant Head
2 Mr.Manoj Jha PPC Head
3 Mr.Rajveer Singh Production (CNC) Engg.
4 Mr.Rakesh Kumar Production (Traub) Production
5 Mr. Om Singh R.I Head
6 Mr.Dilip Sharma Q.A Head
7 Mr.Shushil Kumar Q.A Engg.
Final Inspection
8 Mr Mantosh Incharge
(PDIR)
9 Mr.Chander Shekhar Q.A Engg.
10 Mr.Rajnesh Kumar Q.A Engg.
Prepared By:- Approved By:-
DOC.NO:-F/AQE/24
AQE Training & HR Consultancy Rev.01/Date:-01/10/19
Red Bin Attendance Record
Month:- NOV-2018
S.NO. Name Department
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Mr.R.K
1 Plant Head
Choudhary
2 Mr.Manoj Jha PPC Head
Production
Mr.Rajveer
3 Supervisor
Singh
(CNC)
Production
Mr.Rakesh
4 Head
Kumar
(Traub)
5 Mr.Om Singh R.I Head
SUNDAY
SUNDAY
SUNDAY
SUNDAY
Mr.Dilip Quality
6
Sharma Head
Mr.Shushil
7 Q.C Engg
Kumar
Mr.Manoj
8 Q.C Engg
Sharma
9 Mr.H.Biswal Sr.Engg.
Mr.Rajnesh
10 Q.C Engg
Kumar
10 Mr.Vinay Q.C Engg
Prepared By:- MR Checked By:- QUALITY HEAD Approved By:- PLANT HEAD
ABREVIATION:- P-Present A-Absent SHIFT:- NIGHT-NT
AQE Training & HR Consultancy
ORGANIZATION STRUCTURE ( RED BIN ANALYSIS )
RED BIN PROBLEM SOLVING WHEEL
SUPPORTING MEMBER : -
Mr.R.K Choudhary
Mr.H.Biswal Mr.D.C Sharma
Mr.Rajnesh
Mr.Rakesh Kumar
- PROBLEM
Mr.Rajveer Singh Mr.Sanjeev Chawla
PREPARED BY :- MR APPROVED BY::- PLANT HEAD
कार्य निर्दश
े (W.I)
DOC.NO:- F/AQE/41
REV NO:- 00
EFF. DATE:- 03/12/19
WORK INSTRCUTION FOR RED BIN
मटेरियल को ध्यान पूरव
् क चेक करके रिजेकट् मटेरियल को लाल बिन में रखें
1
रिजेकट् पार्ट शिफ्ट ख़तम होने के बाद फाइनल इंसप
् क
े श
् न के बड़े वाले रेड
2
बिन में रखें
पार्ट को गिनकर वा टैग लगाकर क्वांटिटी के साथ पोली बैग में डालकर
3
ही रेड बिन में रखें
ध्यान रहे की होल्ड मटेरियल के लिए पीले टैग वा रिजेकट् मटेरियल के
4
लिए लाल टैग का प्रयोग करें
टैग के ऊपर पार्ट्स से सम्बध
ं ित साड़ी जानकारी डालें जैसे रिजेकश
् न का
5
कारण क्वांटिटी सभी अवश्य लिखें
हर विसुअल इंसप ् क
े ट् र रिजेकश
् न मटेरियल को रिजेकश
् न शीट में अवश्य
6
डालें पूरी जानकारी के साथ
किसी भी प्रकार की समस्या के आने पर तुरत
ं अपने सुपरवाइजर को सूचित
7
करें
कोई भी रिजेकट् पार्ट को चेक करने के बाद अपने पास न रखें वा उसे लाल
8
टैग लगाकर लाल बिन में ही रखें
रेड बिन मीटिंग का समय 2 बजे निर्धारित किया गया है अतः आप सभी रेड
9
बिन टीम मेब
ं र समय पर रेड बिन एरिया में पहुच
ं े
PREPARED BY:- APPROVED BY:-
Fmt No:-
DAILY REJECTION AT FINAL INSPECTION Rev. No:-
Eff. Date:-
Month:- Jan
30
25
20
Qty 15
10
0
1 2 3 4 5 6 7 8 9 # 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
No. Of Days
Daily Red Bin Analysis Summery
Date of
Operator
Red Effecti
S. No. Component Operation qnty Size Name with Cause/Reason Action Taken Action sss
Bin veness
level
Analys
1 is
2
3
RED BIN analysis sheet
( Analysis of Top 3 defects monthly )
Red Bin Analysis Report
Root Cause (s) :
Date : Corrective Action taken:
Description of the Problem Team Members: S.no. Action Resp
Team Leader :- If repeated, when occurred:
Occurrence : First Time / Repeated
Preventive Action taken:
Root Cause Analysis MATERIAL
MAN
S.no. Action Resp
DEFECT
Horizontal Deployment (if any):
Standardrisation
ENVIRONMENT MACHINE METHOD 1
2
3
S. NO. Potential Cause Resp. Verification Method Verification Data Judgment OK/NG
5 Inspector Asst Mgr
6
Effectiveness monitoring sheet
( Analysis of Top 3 defects monthly )
Date of Operator Cause/Re Action
S. No. Component Operation Qnty Defect Status Effectiveness
Red Name ason Taken
Bin with level
1 Analysi
s
2
