Waste Elimination

Topic 5S Waste Elimination

Waste Eliminatio

M,M,M.

Here , there is no 1M , 2 M ….etc. like 1 S , 2 S….. 5 S

Non- Value Added / Waste

Unevenness / Inconsistency / Imbalance

Overburden / Strain

In a Company people may work HARD , still the RESULT does not lead to an immediate RISE of the PRODUCT VALUE.

While working , we do not know in detail about the operation that is adding value or not adding value.

Operations can be categorized in three types:-

1. Operation that increases value added

2. Operation that does not increase value added

3. Useless operation

So, on broader scale

Let us see one by one .

1. Operation that increases value added

This type of operation is really required for converting Raw material into Finished product

e.g. Grinding / Milling / turning

2. Operation that does not increase value added

This type of operation is inevitable under the present situation but as an operation it does not create any value. ( should be eliminated / reduced )

e.g. De-burring / fettling

3. Useless operation

This type of operation is completely unnecessary. This only increases cost . ( Should be eliminated )

e.g. Re-packing / rework

Hence , it is necessary to LOOK AND SEE in a manner as in the attitude of Questioning.

“ What is the REAL OBJECTIVE of doing so ?” for each and every operation of the manufacturing process.*

Only then , it is possible to visualize & recognize hidden wastes in manufacturing process which otherwise are not seen by us.

Question

* Manufacturing process means every process in a company.. ‘I.e Production, Purchase

HIDDEN WASTE

Output Output

Productivity = ------------- = ------------------------

Input Minimum Input

So , we should get 100 % productivity

But , We never get 100 % Productivity as there is always some amount of HIDDEN WASTE so, we can modify above formula as follow:

Output Output

Productivity = ------------- = ------------------------

Input Input + Waste

7 types of Waste

1. Overproduction

2. Stock

3. Conveyance/ Transport

4. Waiting

5. Operation itself

6. Movement of Operator

7. Defects/ Production of Inferior Goods

Waste on account of

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

1. Overproduction

Overproduction means “ Producing the products in excess quantity which are not required for next operation or Customer.”

1. Overproduction

Operation 1 Operation 2

Required input = 10 / hour

Supplied input = 12 / hour

Output = 10/Hour

1. Overproduction

And what are these jobs ?

1. Overproduction

Operation 1 Operation 2 And for this hidden money , we spend additional money

in following forms ( Next Slide )

1. Overproduction increases

Money spend for - Energy- Record keeping- Documentation- Tooling Cost- Manpower cost- Overheads- Space for Storage- Inventory cost( Reduction in Inventory Turns )-

1. Why ? Overproduction

1. No confidence in process 2. No confidence on set-up Quality3. No confidence on equipment4. No confidence on people ( Operator .. Availability )5. Meaningless increasing efficiency 6. Available = Make Use …. Concept followed

1. How to avoid Overproduction1. Do not produce more than next process demand2. Build confidence in process, set-up 3. Improve m/c condition 4. Improve attendance / Multi-skilling

Indirect ways of reducing over-production1. Reduce Finish Goods area2. Reduce space between two operations 3. Implement 100 % 2 S

1.How to avoid Overproduction ( Contd..)

Management’s role :-•Communicate to all for following the concept... Produce when next process demands. • Decide WIP norms and FG Norms

Overproduction results in

a] Increasing rejection , scrap

b] Reducing CASH-FLOW

c] More searching and sorting

d] BAD 5 S

e] Moving Company towards opposite direction of world Class

Overproduction HIDES

A] Waste of WAITING

B] Waste of MOVEMENT

C] Waste of TRANSPIRATION

D] Waste of PROCESSING or OPERATION

Exercise for the participants

1. Draw a line diagram of your production line / cell / unit

2. Circle those operation where overproduction is done

3. Try to figure out , first hand reasons of overproduction

4. List out possible help / resources required to avoid overproduction including Management's directives

5. Enter numerical value of no. of places where overproduction is taking place in the given chart

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

2. Stock

Stock means HOLDING OF INVENTORIES.

Waste on account of STOCK is a result of OVERPRODUCTION.( Previous waste )

Example :- Stock of Finished products , WIP

2. Stock

Machine failures and defectives in process are reasons for increase in SAFETY STOCK *

* Each company should have a numerical value for safety stock

2. Stock

Improving machine condition and processes will help to reduce necessity of stock

* Each company should have a numerical value for safety stock

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

Conveyance is caused by long distance between two machines / two locations.

This increases material handling and waste of manpower and also chances of damages of products.

Waste of Conveyance can be reduced by Improvement in Layout , eliminating temporary storage methods which need again conveyance of material to final loaction.

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

4. Waiting

It is observed on shop-floor that , operators often wait or watch for the input material which is coming from previous process.

Operator waits for tooling

4. Waiting

Waiting time should minimized by Multi-process operations

Waiting for tools can be eliminated by delivering tools on line ( on Machine )

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

5. Operation itself

In operation , so many activities are carried out which does not add value

Operators are not clear what exactly needs to be done in a particular operation

5. Operation itself

Waste in operation can be reduced by “ Defining clearly work done by machines and work performed by operators”

I.e AUTO and Manual work

AUTO time should be used for handling some other activity or machine

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

While operating a machine or performing any activity on shop-floor , some of movements / motions of operator does not add value

This can be reduced by studying carefully each and every movement / motion of operator and standardizing each activity.

I.e loading place / unloading / lifting place

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

1. Overproduction

2. Stock

4. Waiting

5. Operation itself

Waste on account of

Process produces defectives which either to be reworked or scrapped

This must be reduced / eliminated by process improvement , making processes more capable.

ACHIEVE ZERO DEFECT at EACH STAGE

Overburden / Strain

We have just studied 7 types of waste

Recently added 2 wastes

8. Waste of TALENT

9. Waste of Communication

Overburden / Strain

Unevenness / Inconsistency /

Imbalance

Overburden / Strain

ImbalanceTwo things / activities are having large variation result in losses.

This can be reduced by balancing or reducing Variation

ImbalanceFew examples of reducing losses

a] Balance machine capacities

b] Reduce variation in tooling quality by standardization

c] Share work loads

d] Improve / match skill of the people

Overburden / Strain

Imbalance

Overburden / Strain

Excess usage or exceeding pre-designed capacities result in Strain or Overburden.

This results in lowering life of machines , fatigue of operators ultimately affecting Quality of products and ownership of people

ImbalanceFew examples of reducing losses

a] Balance machine capacities

b] Reduce variation in tooling quality by standardization

c] Share work loads

d] Improve / match skill of the people

Now , we have studied various types of WASTES.

Now it desirable that start improving small problems around you by looking for any type of waste , unevenness or overburden

Waste Elimination

Business

Waste Elimination

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