Faurecia Excellence System

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Group Quality Department

Quality System Efficiency

The 6 Quality Basics -> Red bins

Purpose: Red bins methodologyDefinition, function, examples

Scope: all production sites

FAU-S-PS-0660 / EN issue 01

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Definition and function of red bins

The term red bin refers to a red box, hanger, trolley (cart), rack… that holds non-conforms at any production stage.

The function of red bins is to:immediately separate and isolate non-conforms from the flowexpose the level of non-conforming products rejected by the line or workstationmake it easier for the GAP leader to analyse non-conforms

Isolation and treatment of non-conformsRed bins are intended to receive all BOP (Bought Outside Parts) and semi-finished or finished products pulled off the production line.The red bin must be adjacent to the workstation, close to where the defects are detected.Each part deposited in a red bin is logged. The defective area(s) on every non-conform must be marked with a red sticker, arrow or piece of adhesive tape to facilitate analysis.

Facilitating analysis of non-conforming partsGrouping non-conforms and identifying their defective areas simplifies analysis of the parts. The contents of the red bins are recovered by the GAP leader, who analyses and sorts them (reject or rework, attribution to a supplier or internal defect) and updates the indicators.The UAP quality support function is there to provide assistance in case of new defects, doubts about acceptability, remarks to the supplier and so forth.

Revealing the PPM level of the line (visual management)The red bins must be systematically emptied, at least at the end of the shift.The size of the bin is adapted to the size of the parts and to the admissible reject rate for the line or workstation. Any overflow gives an immediate, visual alert. If this happens, there’s no point in waiting for the end of the shift to analyse the defects.If the parts won’t fit in the bins, a container or holder may be used, on condition that it has permanent red identification (no paper or adhesive tape, which can come off).

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Definition and function of red bins

A few practical remarks• Red bins are reserved exclusively for non-conforms, not for waste or scrap.•Care is needed storing parts to be reworked and “questionable” products; these parts must not be damaged by mishandling after manufacturing and inspection!• Questionable products (where one is uncertain about conformity) must be treated as non-conforms and thus isolated in red bins (no yellow or orange bins!).• A sensitive component (affecting safety/regulation or appearance) which falls on the floor must not be used but isolated in a red bin.

Supplier Faurecia

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General Information

Author :Group QSE

Date : 8 January 2004

Aim of the modification:Complete revision of the previous version

Cancels and replaces:

Associated documents:• FAU S PS 0610• FAU S PS 0620• FAU S PS 0630• FAU S PS 0640• FAU S PS 0650