Red Bin analysis –
Procedure
1. Purpose: To ensure that appropriate actions are being taken on regular basis against in-house rejections.
2. Scope: Applicable to all the types of rejections at various production stages within Organization.
3. Definition: Red bin analysis is a process by which it is ensured that process and quality data is being recorded, rejected parts are being analyzed and
corrective actions are being initiated for its improvement on daily, weekly and monthly basis by CFT.
4. Responsibility: CFT Leader
5. Abbreviations:
CFT: Cross Functional Team: Group of persons with subject matter expertise from various processes
RBA: Red Bin Analysis
CAPA: Corrective and Preventive actions
3G: Genchi (go to the actual place), Genbutsu (see and understand the things), Genjitsu (take the realistic actions)
4M, 1E: 4-Man, machine, methods, material, 1- Environment
PPM: Parts per million
FTT: First time through
OPL: One Point Lesson
ECRN/PCRN: Engineering/Process Change Request Note
FMEA: Failure Mode Effect Analysis
OEE: Overall Equipment Efficiency
Process Flow Chart
INP
UT Capture
Conduct
Make
Conduct
Assign and
defect
cause
Red
display
BinBin
Make
Red &
data
effect
Analysis
attendance
Pareto
PROCESS
Analysisto(4M,1E)
(Defect
find
area and RESP. OUTPU INTERACTION/
Red everyday
wise,
board analysis
Top
SEQUENCE shop
sheet
&wise,
Mark
and
defectat(Weekly,
red
line
assign
attendance
bin
wise,
analysis
potential
model
in T CHECK POINT
meeting; attendance
wise,
causes
machine
Monthly)area Sheet
wise, operator wise, Dept. CFT formation
bin analysis
Time wise etc.) head …… &
S ta r t -QA /PRD communication
Form C F T Team
to
discussion with all
Head -Quality concerned
assurance and team
Production leader
CFT CFT / Annexur CFT meet
Discussion
respective e- 1, location
with
section RBA decided
respective
head- boar
section head
production d
-production layou
t
Conduct Red
bin analysis
CFT Red bin Communicatio
meeting attenda n to all
nc e
sheet
Presence of all
CFT members
CFT / Team Defect
generation
…. Leader information
flow to all
members of
CFT
Defect
generation
CFT Red bin Collection of
information flow analysis defect
to all members data generation
of CFT sheet data
Collected
defect
CFT Red Top defects
generated Bin identification
data Analysi
s top
defect
s trend Potential
CFT
Top defects Red cause(s)
identification Bin identification
Analys
is
report
A
INPUT PROCESS RESP OUTPU INTERACTION/
SEQUENCE . T CHECK POINT
Identified
Validation result
potential
cause(s)
CFT Red of each potential
A Bin
Analysi
s
Validate each potential causes repor cause
through 3G t
Validation
CFT …. Root
result of ea
ch Find out root cause(s)
caus
potential e causes identificatio
n
Root CFT Red CAPA actions
cause(s) Bin
Take corrective & preventive
identificatio Analysis implementation
n actions Summer
y
CAPA
actions
CFT ….. Work Instruction,
Update relevant
impementati INS Std, Drg. Etc.
l on standard &
documents
Implemented
CAPA actions
CFT Red Bin CAPA report
Analysis
top defects
Measures trend
no monitoring
effective?
sheet
ye
s
CAPA CFT Horizontal
report
Horizontal deployment & deployment of
standardization CAPA
implemented
and its
standardization
Appointing the audit team
Defining audit objectives, scope and criteria
Determining the feasibility of the audit
Audit frequency: at least once in
a Fsinixismh onth
Establishing initial contact with the auditee
Red Bin Analysis Board Layout (Recommended):
PREPARED BY: APPROVED BY:
DATE: 01.02.17 DATE: 01.02.17
