Agenda

• Definition
• Keys to the First Pillar
• Why Sort is Important
• How to Implement Sort
• Red Tagging Overview
– Setting Criteria
– Evaluating Items
– Holding Areas
– Disposal Methods
• Summary
• Examples for Discussion
• Application Exercise
 Definition
• Sort means that you remove all
items from the workplace that are
not needed for current production
(or clerical) operations
 Key to the First Pillar
• If you Sort, you leave only the bare essentials.
• When in doubt, remove it from the work area
– This principle is a key part of Sort in the context of the
five pillars.
• Sort does not mean:
– that you throw out only items that you are sure you
will never need.
– that you simply arrange things into neat, straight
patterns.
 Why Sort is Important
• When the first pillar is well implemented:
– problems and annoyances in the work flow
are reduced
– communication between workers is improved
– product quality is increased
– productivity is enhanced
– a work environment is created that allows
for…
• Managed and effectively used resources
– space, time, money, energy, etc
 How to Implement Sort
• The Red-Tag Strategy is a simple method
for:
– identifying potentially unneeded items in the
factory
– evaluating their usefulness
– dealing with them appropriately
 Overview of Red Tagging
• An item with a red tag is asking three
questions:
– Is this item needed?
– If it is needed, is it needed in this quantity?
– If it is needed, does it need to be located
here?
 Steps in Red Tagging
• Step 1: Launch the red tag project
• Step 2: Identify the red tag targets
• Step 3: Set red tag criteria
• Step 4: Make red tags
• Step 5: Attach red tags
• Step 6: Evaluate red tags
• Step 7: Document the results of red
tagging
 Launch the red tag project
• Organize a team
• Organize supplies
• Organize a time or schedule to perform
red tagging
• Setting aside a local red tag holding area
• Planning for disposal of red tagged items
 Identify the red tag targets
• Define the physical area where the red-
tagging will take place
– Offices, Warehouses, Production Area, etc.
• The specific types of items to evaluate
– Inventory (stock), equipment, files and space
 Set Red-Tag Criteria
• The three main factors in determining whether
an item is necessary or not are:
– The usefulness of the item to perform the work at
hand.
• If the item is not needed it should be disposed of.
– The quantity of the item needed to perform this work
• If it is needed in limited quantity the excess can be disposed
of or stored away from the work area.
– The frequency with which the item is needed.
• If it is needed infrequently it can be stored away from the
work area.
 Types of Unneeded Items
• Defective or excess quantities of small parts and
inventory
• Outdated or broken tools, equipment and
inspection gear.
• Worn out equipment
• Old rags and other cleaning supplies
• Electrical equipment with broken cords
• Outdated posters, signs notices and memos
• Documents: On Computers; In Offices
 Places where Unneeded Items
Accumulate
• In rooms or areas not designated for any particular purpose
• In corners next to entrances or exits
• Along interior and exterior walls, next to partitions, and behind walls
• Under the eaves of warehouses
• Under desks and shelves and in desk and cabinet drawers
• Near the bottom of tall stacks of items
• On unused management and production schedule boards
• In tool boxes that are not clearly sorted
• Under stairs
• On Computers (documents)
• In File Cabinets
 Acquire Red Tags
• Red tags should include the following:
– Name of person tagging item
– Date
– Asset no. or Oracle item no.
– Category - general description of item
– Item name and/or number
– Quantity
– Reason
– Condition
– Value
Red Tag Example

Book Value

Item No.

Oracle No.

Condition:
 Attach Red Tags
• It has more impact if the target area is red
tagged as quickly as possible
• Red tag all items in question without
evaluating what to do with them.
Evaluation of Red Tagged Items
• Once the items are identified, they can be
dealt with appropriately. They may be:
– Moved into and held in a “Red-Tag Holding
Area” for a period of time to see whether they
are needed.
– Disposed of.
– Relocated.
– Left exactly where they are until evaluation.
 Red-Tag Holding Area
• A Red-tag holding area:
– is an area set aside for use in storing items
that need further evaluation.
– acts as a safety net between first questioning
whether something is needed and actually
getting rid of that item.
– This buffer is helpful when the need or
frequency of need for that item is unknown.
– This area gives workers time to “let go”.
 Document the Results of
Red-Tagging
• Create a system of logging and tracking
necessary information as red-tagging takes
place
– Logbook
– Spreadsheet
• Documenting results allows the company to
measure the improvements and savings
produced as a result of the red-tagging effort.
• Often companies that think they need to build a
new factory to turn out new products discover
plenty of space when they use the red-tagging
strategy.
Examples of Sort for Discussion
BEFORE AFTER
Examples of Sort for Discussion
BEFORE AFTER
Examples of Sort for Discussion

BEFORE AFTER
Examples of Sort for Discussion
BEFORE AFTER
Examples of Sort for Discussion
BEFORE AFTER
 Summary
• The first pillar is Sort, which means that you
remove all items from the workplace that are not
needed for the current production.
• When in doubt, tag it out.
• When the first pillar is well implemented,
problems and annoyances in the workflow are
reduced, communication between workers in
improved, product quality is increased, and
productivity is enhanced.
Red Tag Examples
 Red Tag Log Register
Last Updated : 05/12/2020 RED TAG LOG REGISTER Rev 0.0
RED TAGGED DATE OF REASON FOR
S.NO AREA TAGGED BY RECOMMENDED ACTION REMARKS/COMMENTS
ITEM(NAME/DESCRIPTION) TAGGING TAGGING
Service engineer visiting
1 ACS 850 VFD MCC Room Dipti 20-08-17 Defect Not applicable
site for repairing

2 Bag Compressing Machine Lime warehouse Bala 14-06-16 Not required Return/Sell

Near process water

3 Spencer motor Dipti 08-04-17 Not required relocate Use as a spare
tank
Near process water
4 RAV Aniket 05-04-18 Defect/Scrap Scrap
tank
Waiting for service
5 CT water distributor pipes Near Scrubber Manas 13-11-19 Not required relocate
engineer visit
Process building
6 Spencer Manas 14-04-19 Not required relocate Installed at position
entrance
Control room back
7 Spencer Nanaji 10-06-18 Defect/Scrap Scrap
side
After repairing, fix it to
8 Incoming braker MCC Room Dipti 10-11-19 Defect Need to repair working bus bar
connection
To be used as & when
9 Cooling tower fan Near Cooling tower Manas 20-09-19 Not required relocate
required
Process building To be used as & when
10 Slaker paddles Manas 02-05-19 Not required relocate
entrance required
Near Carb-2 To be used as & when
11 Demister/Chevron Pavan 05-06-19 Not required relocate
agitator required
To be used as & when
12 Cooling tower fan Near Cooling tower Manas 17-11-19 Not required relocate
required
Near slake hold To be used as & when
13 Lube oil (all 5 drums) Manas 07-05-19 Not required relocate
tank required
Maintenance To be used as & when
14 High speed pedestrian fan Dipti 17-11-19 Not required relocate
workshop required

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