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
INPUT Capture
Conduct
Make
Conduct
Assign and
defect
cause
RedMake
Red
display
BinBin
&
data
Pareto
effect
PROCESS Analysis
attendance
(Defect
to
(4M,1E)
find
SEQUENCE
Analysis everyday
area wise,
sheet
andanalysis
shop
at
&
board RESP. OUTPUT INTERACTION/
Mark
wise,
Top
and
attendance
line
red
defect
assign
wise,
bin(Weekly,
analysis
model
potential
in attendance
wise,
area
Monthly)
causes
machine
Sheet CHECK POINT
Red bin analysis
wise, operator wise, Time wise etc.) Dept. head …… CFT formation &
meeting;
FormStart
CFT Team -QA /PRD communication to
discussion with all concerned
Head -Quality team leader
assurance and
Production

CFT Discussion CFT / Annexure- CFT meet

with respective respective 1, RBA location decided
section head section head- board
-production production layout

Conduct Red bin CFT Red bin Communication

analysis meeting attendanc to all
e sheet

Presence of all CFT CFT / Team …. Defect generation

members Leader information flow
to all members of
CFT

Defect generation CFT Red bin Collection of

information flow to analysis defect generation
all members of CFT data sheet data

Collected defect CFT Red Bin Top defects

generated data Analysis identification
top
defects
trend
Top defects CFT Red Bin Potential cause(s)
identification Analysis identification
report

A
INPUT PROCESS SEQUENCE RESP. OUTPUT INTERACTION/
CHECK POINT
Identified potential CFT Red Bin Validation result of
cause(s) A Analysis each potential
Validate each potential causes through report cause
3G

Validation result CFT …. Root cause(s)

of each potential Find out root causes identification
cause

Root cause(s) CFT Red Bin CAPA actions

Take corrective & preventive actions
identification Analysis implementation
Summery

CAPA actions CFT ….. Work Instruction,

Update
implementation relevant standard & INS Std, Drg. Etc.
documents

Implemented CAPA CFT Red Bin CAPA report

actions Analysis top
defects trend
Measures monitoring
no sheet
effective?

yes

CAPA report CFT Horizontal

Horizontal deployment & standardization deployment of
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 aFinish
six month
Establishing initial contact with the auditee

Red Bin Analysis Board Layout (Recommended):

PREPARED BY: APPROVED BY:
DATE: 01.02.17 DATE: 01.02.17