5S RED TAG CAMPAIGN METHODOLOGY

5S RED TAG CAMPAIGN POSTERS

Dear Colleagues,

2S, Orderliness and Cleanliness is fundamental upon which we can build all our initiatives. In order to strengthen our 2S improvement activitiesit is necessary to remove unncessary items from gemba time to time.

What is RED tag campaign ?

Identifying & Sorting out the the unnecessary items from our work place.

Why Red tag campaign?

• To sort out unnecessary items from gemba and separate / dispose them.

• To reduce time required for searching of items in day to day work.

• To minimise storage space

• To create a safe, clean and cheerful workplace

How to do the Red tagging?• Look around your work place & Identify unneccessary items.

Ex: Unused jigs/ fixture/ files, broken/ damaged tools/ trolleys/ furnitures etc

• Fill up the "red tag" with help of supervisors / cell leaders.• Attach red tags to unneccessary items• Safely move unneccessary items to red tag area with red tag.

• Don’t tag and move PSN , MSN, RT components.

Request everybody’s co-operation

Inform to your superior before tagging.

Red tag forms available at unit / dept office.

5S RED TAG CAMPAIGN

Tagging Frequency & Duration :

Twice in a month, First Thursday in First week of every month and second Thursday in

Third week , Companywide

First campaign : Second campaign :

Operation dept : 45 min (2.00 –2.45 PM),

Other Depts : 2 to 3hours (1.15 pm onwards)

On the day: During red tag campaign time slot –

• No meetings (avoid meetings with customers , visitors, suppliers)

• No air, No power..

Audit to be done by GM, MFG - HEAD, ALL HOD’S.

5S RED TAG CAMPAIGN - OBJECTIVE

Identification & separation of “unnecessary items”

in & around the work place by involving everybody

to achieve a Safe & Clean work place.

“ It’s wasteful to throw things away ! ”

“ It was so much difficult for me to make these things ! ”

“ We might possibly use these things later ! ”

(These are the common / natural reactions to the idea of getting rid of

unnecessary items, whether it be at home or in the factory).

What are the “UNNECCESSARY” items ? ….

Items that are “not needed for present production”.

It can be…

• Unused (during the last 6 month or 1 year, standard to be set by dept)

• Obsolete

• Unrepairable

• Damaged

• Not going to be use in near future

“ Good workshops develop beginning with 5Ss ”

What do we attach red tags to ? ….

Unused, Obsolete, Damaged, Not going to be use in near future ….

Machines, Facilities, Parts,

Products, Raw materials, Racks

Containers, Jigs & Fixtures,

Stationery, Documents, Furnitures ….etc.

“ Bad workshops fall apart beginning with 5Ss ”

Fix up red tag standards - Resp: Managers

• Decide & Fix standards for unnecessary items depends upon

production pattern or nature of job involved in the department.

• Decide standard ( 1 month or 1 week or 3 month or else )

and communicate about standards for

“what is really needed” & “ what is not needed”

Retain items to be used within “STANDARD”, Tag everything else.

Red tag guidelines ….

FREQUENCY OF USE

GUIDELINES

Not used in last 1 years Throw them out

Used only once in the last 6 - 12 months

Store them at a distance

Used only once in the last 1 - 6 months

Store them at a central place nearer to the workplace

Used more than once a month or unused weekly / daily / hourly.

Store near the workplace

“ The difficulty things are easy, But The Easy things elude you ”

Unit / Dept managers has to decide on storage location / place, method, qty based on their convinient or requirement

Pre – requisites Resp : Section / managers, Planners

• Identify and earmark a location with RED adhesive tape.

( location temporary, floor space appropriately )

• Each sections should have a separate RED tag area

(including tool crib, tool room, standards room,labs etc)

• Collect RED tag from stores.

• Display the RED tag campaign posters- English / Tamil (Resp :Supervisors).

• Communicate the RED tag time, duration to workmen.

• Train the workmen on RED tag campaign using posters.

• Communicate the RED tag standard to subordinates.

Where to apply red tag standards ? ….

Shelves, Cupboards, Storage Racks, Boxes, Stands

Passage ways, Corners, Near partitions / pillars /

Parts supermarket, WIP storage locations

Tools cabinets, Jigs & Fixture storage places

Contigency parts storage locations

Inspection / Gauges stands

Near Measurement devices ( Pre-setters, Surface tables)

Oil / Chemicals / Consumables storage places

Audit stations, Tables, Display boards, .

Red Tagging ….in Shop floor (Operations)

Identify the unnecessary items SP, CL, WM

Fill up the tag SP, CL, WM

Give serial no. to red tags CL, WM

Tied one tag on each unnecessary item WM

Move the item to Red tag location CL,WM

Enter the item in red tag “items list” MC

Decide “action” on red tagged items APH, Mfg - Head, HOD’S

SP –Supervisor, CL – cell leader, WM – Work men

Red Tagging ….in Shop floor (Operations)

1. During Red tagging time – unit managers & module controllers should ‘go around’ the shop floor to monitor, help / guide workmen in red tagging.

2. Do red tagging afterwards in your unit office area .

3. Identify and communicate responsibility -areawise / cellwise / bay wise.

4. Allocate responsibility for tagging in common areas like,

RT area, Gang ways / Display boards Raw mateiral / finished parts - supermarketFixtures / Oil storage area & etc.

5. In assembly sections employees to be allocated for red tagging near conveyor, sub assembly, supermarkets, washing area, RT & testing areas etc.

V MACHINE V TOOLS & GAUGES V WORK IN PROCESS V FINISHED PRODUCT

V EQUIPMENT V RAW MATERIAL V FILES & DOCUMENTS V SAMPLE ITEMS

V JIGS & FIXTURES V BOUGHT OUT V FURNITURE V ---------------------------

V UNNECESSARY /UNUSED V REJECTED V NOT IN PROPER LOCATION V MIX UP

V OBSOLETE V DEFECTIVE V UNKNOWN/UNFINISHED V --------------------------

V MOVE TO DUST BIN V MOVE TO PROPER LOCATION V RETURN TO SUPPLIER V --------------------------

V MOVE TO SCRAP V SEGREGATE V RECTIFY YARD WITH DOC

RESPONSIBILITY NAME DEPT SECTION ACTION COMPLETED

TARGET DATE FOR COMPLETING ACTION SIGN / DATE SIGN / DATE ACTION BY SPECIFIC INSTRUCTIONSDEPT

LETTER SENT TO V PED LETTER REF

V PMD V CIVIL V-----------

APPROX VALUE Rs

TAG DATE

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ALLOTTED BY SECTION HEAD

INIT

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BY

5S RED TAGIDENTIFIED FOR CLEARING FROM THE LOCATION)

DEPARTMENT

NAME OF THE ITEM

SECTION

QTY

5S RED TAG( IDENTIFIED FOR CLEANING FROM THE LOCATION )

5S RED TAG

Attach red tag to each major items and lots of minor/spillage / mixed / assorted items

Evaluation & Action ….

Material / Tools stock

Defective items - Discard

Obsolete items - Discard

Retained stock - Move to storage

Equipments / Facilities

• Anything which interfere with improvement activities

shall be eliminated.

Important note…

1. Keep red tagged items neatly, without touching each other in red tage area

2. Ensure safety while moving items.

3. Ensure safety / follow disposal instructions while disposing

chemicals and hazardous materials. If in doubt ask concerned manager.

3. Ensure that “confidential” papers / drawings etc. shall not be disposed

as it is. Get approval with concened GMs / HODs.

4. Get ISD help for safe disposal of printer cartridges and e-wastes.

5. Get PMD’s help to move heavy machines, equipments etc.

6. Get CIVIL dept’s help to move the ‘red tag’ items to scrap yard (with proper approval documents)

Role of Dept / Plant manager

• Initiate clearing of fixed assets

• Conduct review on Red tag campaign (audit, adherence, clearance, etc).

Role of Unit / Section manager

• Educate, Communicate, Motivate to involve everyone

• Monitor the process of red tagging

• Decide actions & ensure clearance of red tagged items on time

Role of Module controllers

• Identify unnecessary items

• Verify content of red tags

• Ensure movement of “items” to red tag area.

• Ensure that nobody hide unnecessary / defective items.

• Prepare summary list and dispose the items

Role of Workmen

• Identify unnecessary items.

• Move red tagged items to red tag area with supervisor’s knowledge.

Role of Cell leaders• Identify unnecessary items, Fill up red tags & Move items to red tag area.

Motivation :

Encourage employees ,

- by supporting them to implement their suggestions (check for side effect if any,

feasibility, acceptability, time limit etc) on salvaging / rectifying red tagged items.

- by assigning them to find an “use” of red tagged items in some other area.

- by giving award for their suggestion on above based on “one time savings

savings – certified by Accounts dept.” as applicable to our TEIAN system.

5S RED TAG CAMPAIGN

Items clearance time limit:

With in 10 days for capital items, other items with in 3 days from campaign day.

5S RED TAG CAMPAIGN

.

Clearance of minor items / stationeries :

Responsibility

Simple items : MFG - HEAD

Tools / Fixtures in shop floor: APH & Plant Maintenance manager

Testing / inspection equipments,Gauges : Plant Maintenance manager along with PED section head, Standards room

incharge as appropriate.

5S RED TAGGED ITEMS SUMMARY LIST Dept / Unit :

S. No.

Tag No.

ITEM DESCRIPTION QTYUnit / Section

manager signature

Estimated Cost (Rs.in Lacs)

Action to be taken

Moved to Red tag area on

Date

Executive / Supervisor /

Planner signature

Use PRINT OUT of this for preparing summary

Prepare unit / section wise summary of items moved to red tag area .

THANKS