waste elimination

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Topic 5S Waste Elimination

Waste Eliminatio

n

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M,M,M.

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

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Non- Value Added / Waste

Unevenness / Inconsistency / Imbalance

Overburden / Strain

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

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

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“ 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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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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7 types of Waste

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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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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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1. Overproduction

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

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1. Overproduction

Operation 1 Operation 2

Required input = 10 / hour

Supplied input = 12 / hour

Output = 10/Hour

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1. Overproduction


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1. Overproduction


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1. Overproduction


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1. Overproduction


And what are these jobs ?

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1. Overproduction


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1. Overproduction

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

in following forms ( Next Slide )

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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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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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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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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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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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Overproduction HIDES

A] Waste of WAITING

B] Waste of MOVEMENT

C] Waste of TRANSPIRATION

D] Waste of PROCESSING or OPERATION

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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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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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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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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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2. Stock

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

* Each company should have a numerical value for safety stock

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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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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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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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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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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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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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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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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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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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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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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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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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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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1. Overproduction

2. Stock


4. Waiting

5. Operation itself



Waste on account of

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Process produces defectives which either to be reworked or scrapped

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

ACHIEVE ZERO DEFECT at EACH STAGE

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Overburden / Strain

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We have just studied 7 types of waste

Recently added 2 wastes

8. Waste of TALENT

9. Waste of Communication


Overburden / Strain

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Unevenness / Inconsistency /

Imbalance

Overburden / Strain

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

This can be reduced by balancing or reducing Variation

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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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Overburden / Strain

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Imbalance

Overburden / Strain

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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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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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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

overproduction operation

waste elimination

types of waste

movementof operator

conveyance transport4

previous waste example

shouldbeeliminated e

e production