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1
Topic 5S Waste Elimination
Waste Eliminatio
n
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Topic 5S Waste Elimination
M,M,M.
Here , there is no 1M , 2 M ….etc. like 1 S , 2 S….. 5 S
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Topic 5S Waste Elimination
Non- Value Added / Waste
Unevenness / Inconsistency / Imbalance
Overburden / Strain
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Topic 5S Waste Elimination
In a Company people may work HARD , still the RESULT does not lead to an immediate RISE of the PRODUCT VALUE.
WHY
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Topic 5S Waste Elimination
While working , we do not know in detail about the operation that is adding value or not adding value.
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Topic 5S Waste Elimination
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 .
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
3. Useless operation
This type of operation is completely unnecessary. This only increases cost . ( Should be eliminated )
e.g. Re-packing / rework
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Topic 5S Waste Elimination
Hence , it is necessary to LOOK AND SEE in a manner as in the attitude of Questioning.
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Topic 5S Waste Elimination
“ 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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
7 types of Waste
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
1. Overproduction
Overproduction means “ Producing the products in excess quantity which are not required for next operation or Customer.”
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Topic 5S Waste Elimination
1. Overproduction
Operation 1 Operation 2
Required input = 10 / hour
Supplied input = 12 / hour
Output = 10/Hour
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Topic 5S Waste Elimination
1. Overproduction
Operation 1 Operation 2
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Topic 5S Waste Elimination
1. Overproduction
Operation 1 Operation 2
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Topic 5S Waste Elimination
1. Overproduction
Operation 1 Operation 2
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Topic 5S Waste Elimination
1. Overproduction
Operation 1 Operation 2
And what are these jobs ?
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Topic 5S Waste Elimination
1. Overproduction
Operation 1 Operation 2
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Topic 5S Waste Elimination
1. Overproduction
Operation 1 Operation 2 And for this hidden money , we spend additional money
in following forms ( Next Slide )
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Topic 5S Waste Elimination
1. Overproduction increases
Money spend for - Energy- Record keeping- Documentation- Tooling Cost- Manpower cost- Overheads- Space for Storage- Inventory cost( Reduction in Inventory Turns )-
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
Overproduction HIDES
A] Waste of WAITING
B] Waste of MOVEMENT
C] Waste of TRANSPIRATION
D] Waste of PROCESSING or OPERATION
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Topic 5S Waste Elimination
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
33
Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
2. Stock
Improving machine condition and processes will help to reduce necessity of stock
* Each company should have a numerical value for safety stock
37
Topic 5S Waste Elimination
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
38
Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
3. Conveyance/ Transport
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.
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Topic 5S Waste Elimination
3. Conveyance/ Transport
Waste of Conveyance can be reduced by Improvement in Layout , eliminating temporary storage methods which need again conveyance of material to final loaction.
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Topic 5S Waste Elimination
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
42
Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
4. Waiting
It is observed on shop-floor that , operators often wait or watch for the input material which is coming from previous process.
OR
Operator waits for tooling
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Topic 5S Waste Elimination
4. Waiting
Waiting time should minimized by Multi-process operations
Waiting for tools can be eliminated by delivering tools on line ( on Machine )
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
5. Operation itself
In operation , so many activities are carried out which does not add value
OR
Operators are not clear what exactly needs to be done in a particular operation
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
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
50
Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
6. Movement of Operator
While operating a machine or performing any activity on shop-floor , some of movements / motions of operator does not add value
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Topic 5S Waste Elimination
6. Movement of Operator
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
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Topic 5S Waste Elimination
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
54
Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
7. Defects/ Production of Inferior Goods
Process produces defectives which either to be reworked or scrapped
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Topic 5S Waste Elimination
7. Defects/ Production of Inferior Goods
This must be reduced / eliminated by process improvement , making processes more capable.
ACHIEVE ZERO DEFECT at EACH STAGE
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Topic 5S Waste Elimination
Non- Value Added / Waste
Unevenness / Inconsistency / Imbalance
Overburden / Strain
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Topic 5S Waste Elimination
Non- Value Added / Waste
We have just studied 7 types of waste
Recently added 2 wastes
8. Waste of TALENT
9. Waste of Communication
Unevenness / Inconsistency / Imbalance
Overburden / Strain
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Topic 5S Waste Elimination
Non- Value Added / Waste
Unevenness / Inconsistency /
Imbalance
Overburden / Strain
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Topic 5S Waste Elimination
Unevenness / Inconsistency /
ImbalanceTwo things / activities are having large variation result in losses.
This can be reduced by balancing or reducing Variation
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Topic 5S Waste Elimination
Unevenness / Inconsistency /
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
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Topic 5S Waste Elimination
Non- Value Added / Waste
Unevenness / Inconsistency / Imbalance
Overburden / Strain
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Topic 5S Waste Elimination
Non- Value Added / Waste
Unevenness / Inconsistency /
Imbalance
Overburden / Strain
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Topic 5S Waste Elimination
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
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Topic 5S Waste Elimination
Unevenness / Inconsistency /
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
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Topic 5S Waste Elimination
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