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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 activities it 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. Dont tag and move PSN , MSN, RT components.

 Inform to your superior before tagging.  Red tag forms available at unit / dept office.

Request everybodys co-operation

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 HODS.

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.

Its 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
Not used in last 1 years

GUIDELINES
Throw them out

Used only once in the last 6 - 12 months Used only once in the last 1 - 6 months

Store them at a distance

Store them at a central place nearer to the workplace Store near the workplace

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

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

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

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 Fill up the tag Give serial no. to red tags Tied one tag on each unnecessary item Move the item to Red tag location Enter the item in red tag items list Decide action on red tagged items

SP, CL, WM SP, CL, WM CL, WM WM CL,WM MC APH, Mfg - Head, HODS

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. Do red tagging afterwards in your unit office area . Identify and communicate responsibility -areawise / cellwise / bay wise. Allocate responsibility for tagging in common areas like, RT area, Gang ways / Display boards Raw mateiral / finished parts - supermarket Fixtures / Oil storage area & etc.

2. 3. 4.

5.

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

5S RED TAG
( DENT F ED F R CLEAN NG FR M THE L CAT N ) DEPARTMENT

SECT N QTY

NAME N

F THE TEM

APPR X VAL E Rs

CLASS F CAT

MACH NE EQ PMENT J GS & F XT RES


LS & GA GES

W RK N PR CESS F LES & D C MENTS F RN T RE


F N SHED PR D CT SAMPLE TEMS --------------------------

RAW MATER AL B GHT


REAS N

NNECESSARY / N SED BS LETE


REJECTED DEFECT VE M VE T PR PER L CAT N SEGREGATE


N T N PR PER L CAT N NKN WN/ NF N SHED


MX P ---------------------------------------------------

M VE T D ST B N N ACT M VE T SCRAP YARD W TH D C


RET RN T S PPL ER RECT FY

ttach red tag to each major items and lots of minor/spillage / mixed / assorted items
N RESP NS B L TY NAME DEPT SECT N ACT N C MPLETED ALL TTED BY SECT N HEAD N T ATE ACT

S GN / DATE

S GN / DATE

ACT

N BY

ACT N BY DEPT

SPEC F C NSTR CT NS

LETTER SENT T

PED

PMD

CVL

----------- LETTER
REF

TARGET DATE F R C MPLET NG ACT N


TAG DATE

Evaluation & Action .


Material / Tools stock Defective items Obsolete items Retained stock Equipments / Facilities Discard Discard Move to storage

Anything which interfere with improvement activities shall be eliminated.

Important note
1. 2. 3. Keep red tagged items neatly, without touching each other in red tage area Ensure safety while moving items. 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. 5. 6. Get ISD help for safe disposal of printer cartridges and e-wastes. Get PMDs help to move heavy machines, equipments etc. Get CI IL depts 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 Cell leaders


Identify unnecessary items, Fill up red tags & Move items to red tag area.

Role of Workmen
Identify unnecessary items. Move red tagged items to red tag area with supervisors knowledge.

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.

5
. N . N .

GG

LI
i C .i L i l i i / /

Dept / U it :

U i / i i

C I

I N

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

 Use PRINT OUT of this for preparing summary

THANKS