REAL WORKPLACE (GEMBA)

Sort out and separate needed & not needed.

Put what is needed in order, so that they are ready for use when

needed

Clean workplace, equipment and prevent defects

Self-discipline and training

Standardize, make habit of sorting, straightening and cleaning routine

Seiri

Seiton

Seiso

Seiketsu

ShitsukeSorting out

Place for EverythingEverything in its place Standardization

Cleaning is Inspection Self Discipline

FIVE “S”

1

2

3

4

5

1. Seiri - Sort Out and Separate

Waste paper

Scrapspares

Scrap iron

Separate unnecessary from the necessary

Action ?

Article

becomes needed

Y N

Computer

Old typewriter

x

x Separate and

either sell or

scrap

Store at a defined place and/or use

Analyze your job !

1. Seiri - Sort Out and Separate

CATEGORISE

Not Needed at all Needed but not Now

Needed but Not Here

Needed but surplus Qty.

Pending For Decision

Catagorise

Apply Red Tag(akafuda)

RED TAG• TAG NO.

• MADE ON ……………..

• MADE BY ....................

• GEMBA ……………..

DECISION:

NOT NEEDED AT ALL NEEDED, BUT NOT NOW

NEEDED, BUT NOT HERE

NEEDED, BUT QTY SURPLUS

PENDING FOR DECISION

Red Tag Tactic : Visual Sorting.

This is a vital Sorting Technique

As soon as any unnecessary item is

identified, it is marked with red tag so that

anybody can see clearly, what needs to be

eliminated or moved.

The use of red tags can be the key to a company’s

survival.

What is the Red Tag Tactic ?

PROCEDURE FOR RED TAGGING

PROCEDURE FOR RED TAGGING- Checkpoints follow….

Equipment - Move items that hinder the implementation of 5 ‘S’ activities.

Stock – List unnecessary stock, by dividing into obsolete stock and slow moving stock.

It’s important that everybody can see them at a glance!• Red paper• Include name of item, quantity, reasons, etc.

• Directly concerned people to attach !• No excuses permitted !• Be strict about it !

• Attach tags to any doubtful item !• The number of tags indicates checking efficiency !

Procedure For RED TAGGINGCheckpoints

Red tag anything that is not needed !

In manufacturing departments that means

checking stock, machines, equipment,

particular locations such as shelves , etc.

In clerical departments it includes documents,

stationery and machines .

However, you should never ever red tag

people, even if you are sometimes tempted to!

WHAT DO WE ATTACH RED TAGS TO ?

1. Documents : Notices, circulars, minutes, reports,

drafts, quotations,memos, statistical data.

2. Fittings : Folders , binders , document files,cabinets

lockers, boxes for materials, desks, chairs.

3. Stationery : Pencils, propelling pencils, ball-point pens,

felt –tip pens, erasers, clips , memo pads etc.

4. Others : Slips, visiting cards, books, magazines,

newspapers, plans, pamphlets etc.

WHAT DO WE ATTACH RED TAGS TO ?

Checkpoints

4. Stock :- Raw materials, parts, work-in- progress,

5. component parts, finished products.

6. Facilities :- Machines, equipment ,jigs, tools cutting

7. tools, molds, fittings, carts, pallets , lifts,

8. work tables, vehicles, desks, chairs.

9. Locations :- Floors, shelves, rooms.

10. computers, facsimile machines, shredders.

11. Machines :- Copy machines, word processors, personal

WHAT DO WE ATTACH RED TAGS TO ?

Checkpoints

Participants – Scientists, Engineers, Technicians etc.Period - 10-15 daysRemember – Do not hide non-required items.

Stock – R/M & P/MEquipment/ gauges etc. Spaces - Floor, Shelves, Storage

Clarify standards for unnecessary items :eg. ‘NO TAG’ for items to be used within th next month; ‘TAG ON’ for items not to be used within the next month.

Procedure For RED TAGGING- Checkpoints

Factories are like people -they sweat and get dirty. People deal with this problem by bathing. The red-tag strategy was devised

as a way to periodically wash off the factory's

accumulated oil, dirt, and grime

Practical Examples

Practical Examples

Practical Examples

Practical Examples – Red Tag Campaign

Audit Format

CHECK LIST FOR UNNECESSARY ITMES DEPT:AT WORKPLACE DATE AUDITOR

Sr. No. CHECKPOINT MARKS ACTION PLANNED1 Are there any Unused items in Storage?

2Is there anything in the Aisles which is not in use?

3 Are there any Unnecessary Machines?

4Are there any Unnecessary items or or under Shelves?

5Are there any Unncessary items around or under Machines?

CriteriaNo Non Confirmities = 4 Marks2 Non Confirmities = 2 MarksMore than 2 N.C's = 0 Marks

THANK YOU