Waste Elimination
 M M M 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  V...
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 ...
1.  Operation  that  increases  value  added This  type  of  operation  is  really  required  for  converting  Raw  materi...
2.  Operation  that  does not  increase  value  added  This  type  of  operation  is  inevitable under  the  present  situ...
3.  Useless operation   This  type  of  operation  is  completely  unnecessary. This  only  increases  cost  .  (  Should ...
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.*  On...
HIDDEN  WASTE   Output   Output Productivity  =  -------------  =  ------------------------   Input    Minimum  Input So  ...
7 types of Waste
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction Overproduction  means  “ Producing  the  products  in excess quantity which are  not  required for  next...
1. Overproduction Operation 1  Operation 2  Required   input  =  10  / hour  Supplied   input  =  12 / hour  Output  = 10/...
1. Overproduction Operation 1  Operation 2  After 1 hour
1.  Overproduction Operation 1  Operation 2  After 2 hour
1. Overproduction Operation 1  Operation 2  After 3 hour
1.  Overproduction Operation 1  Operation 2  After 10 hours And  what  are  these  jobs ?
1.  Overproduction Operation 1  Operation 2  This  is  Hidden Money
1. Overproduction Operation 1  Operation 2  This  is  Hidden Money And  for  this  hidden  money  , we  spend  additional ...
1. Overproduction  increases  This  is  Hidden Money Money  spend  for  - Energy - Record keeping - Documentation - Toolin...
1. Why  ?  Overproduction This  is  Hidden Money 1.  No  confidence  in  process  2. No confidence  on  set-up  Quality 3....
1. How  to  avoid  Overproduction This  is  Hidden Money 1.  Do  not  produce  more  than  next  process  demand 2. Build ...
1.How  to  avoid  Overproduction  ( Contd..) This  is  Hidden Money <ul><li>Management’s  role :- </li></ul><ul><li>Commun...
Overproduction  results  in  This  is  Hidden Money a]  Increasing  rejection  , scrap  b] Reducing  CASH-FLOW c]  More  s...
Overproduction  HIDES  This  is  Hidden Money A] Waste  of  WAITING B] Waste  of  MOVEMENT  C]  Waste  of  TRANSPIRATION  ...
World class Overproduction Worst class
Exercise  for  the  participants  1.  Draw  a  line  diagram  of  your  production line / cell / unit  2. Circle  those  o...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
2. Stock Stock  means  HOLDING  OF  INVENTORIES. Waste  on  account  of  STOCK  is  a  result  of  OVERPRODUCTION.( Previo...
2. Stock Machine  failures  and  defectives  in  process  are  reasons  for  increase   in SAFETY  STOCK * *  Each  compan...
2. Stock Improving  machine  condition  and  processes  will  help  to  reduce  necessity  of  stock *  Each  company  sho...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
3. Conveyance/ Transport  Conveyance  is  caused  by  long  distance  between  two  machines / two  locations. This  incre...
3. Conveyance/ Transport  Waste  of  Conveyance  can  be  reduced  by  Improvement  in  Layout , eliminating  temporary  s...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
4. Waiting  It  is  observed  on  shop-floor  that  , operators  often  wait  or watch  for  the  input  material which  i...
4. Waiting  Waiting  time  should  minimized  by  Multi-process  operations  Waiting  for  tools  can  be  eliminated  by ...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
5. Operation  itself  In  operation  ,  so  many  activities  are  carried  out  which  does not  add  value  OR  Operator...
5. Operation  itself  Waste  in operation  can  be  reduced  by “  Defining  clearly  work  done  by  machines  and  work ...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
6. Movement  of Operator While  operating  a  machine  or  performing  any  activity  on  shop-floor , some  of  movements...
6. Movement  of Operator This  can  be  reduced  by  studying carefully each and  every  movement / motion  of  operator  ...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
1. Overproduction 2. Stock 3. Conveyance/ Transport  4. Waiting 5. Operation itself 6. Movement  of Operator 7. Defects/ P...
7. Defects/ Production  of  Inferior Goods   Process  produces defectives  which  either  to  be  reworked  or  scrapped
7. Defects/ Production  of  Inferior Goods This  must  be  reduced /  eliminated  by  process  improvement  , making  proc...
Non- Value Added /  Waste  Unevenness / Inconsistency / Imbalance    Overburden /  Strain
Non- Value Added /  Waste   We  have  just  studied  7 types of  waste  Recently  added  2  wastes  8. Waste  of  TALENT 9...
Non- Value Added /  Waste   Unevenness / Inconsistency / Imbalance Overburden /  Strain
Unevenness / Inconsistency / Imbalance Two  things  / activities  are  having  large  variation  result  in losses.  This ...
Unevenness / Inconsistency / Imbalance Few  examples  of  reducing  losses  a] Balance  machine  capacities  b] Reduce var...
Non- Value Added /  Waste  Unevenness / Inconsistency / Imbalance    Overburden /  Strain
Non- Value Added /  Waste   Unevenness / Inconsistency / Imbalance Overburden /  Strain
Overburden /  Strain Excess  usage  or  exceeding  pre-designed  capacities  result  in  Strain  or  Overburden. This  res...
Unevenness / Inconsistency / Imbalance Few  examples  of  reducing  losses  a] Balance  machine  capacities  b] Reduce var...
Now ,  we  have  studied  various  types  of  WASTES. Now  it  desirable  that  start  improving  small  problems  around ...
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Waste Elimination

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Waste Elimination

  1. 1. Waste Elimination
  2. 2.  M M M M, M, M. Here , there is no 1M , 2 M ….etc. like 1 S , 2 S….. 5 S
  3. 3. Non- Value Added / Waste Unevenness / Inconsistency / Imbalance Overburden / Strain
  4. 4. In a Company people may work HARD , still the RESULT does not lead to an immediate RISE of the PRODUCT VALUE . WHY
  5. 5. While working , we do not know in detail about the operation that is adding value or not adding value.
  6. 6. 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 .
  7. 7. 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
  8. 8. 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
  9. 9. 3. Useless operation This type of operation is completely unnecessary. This only increases cost . ( Should be eliminated ) e.g. Re-packing / rework
  10. 10. Hence , it is necessary to LOOK AND SEE in a manner as in the attitude of Questioning.
  11. 11. “ 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
  12. 12. 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
  13. 13. 7 types of Waste
  14. 14. 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
  15. 15. 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
  16. 16. 1. Overproduction Overproduction means “ Producing the products in excess quantity which are not required for next operation or Customer.”
  17. 17. 1. Overproduction Operation 1 Operation 2 Required input = 10 / hour Supplied input = 12 / hour Output = 10/Hour
  18. 18. 1. Overproduction Operation 1 Operation 2 After 1 hour
  19. 19. 1. Overproduction Operation 1 Operation 2 After 2 hour
  20. 20. 1. Overproduction Operation 1 Operation 2 After 3 hour
  21. 21. 1. Overproduction Operation 1 Operation 2 After 10 hours And what are these jobs ?
  22. 22. 1. Overproduction Operation 1 Operation 2 This is Hidden Money
  23. 23. 1. Overproduction Operation 1 Operation 2 This is Hidden Money And for this hidden money , we spend additional money in following forms ( Next Slide )
  24. 24. 1. Overproduction increases This is Hidden Money Money spend for - Energy - Record keeping - Documentation - Tooling Cost - Manpower cost - Overheads - Space for Storage - Inventory cost( Reduction in Inventory Turns ) -
  25. 25. 1. Why ? Overproduction This is Hidden Money 1. No confidence in process 2. No confidence on set-up Quality 3. No confidence on equipment 4. No confidence on people ( Operator .. Availability ) 5. Meaningless increasing efficiency 6. Available = Make Use …. Concept followed
  26. 26. 1. How to avoid Overproduction This is Hidden Money 1. Do not produce more than next process demand 2. Build confidence in process, set-up 3. Improve m/c condition 4. Improve attendance / Multi-skilling Indirect ways of reducing over-production 1. Reduce Finish Goods area 2. Reduce space between two operations 3. Implement 100 % 2 S
  27. 27. 1.How to avoid Overproduction ( Contd..) This is Hidden Money <ul><li>Management’s role :- </li></ul><ul><li>Communicate to all for </li></ul><ul><li>following the concept... Produce when </li></ul><ul><li>next process demands. </li></ul><ul><li>Decide WIP norms and FG Norms </li></ul>
  28. 28. Overproduction results in This is Hidden Money 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
  29. 29. Overproduction HIDES This is Hidden Money A] Waste of WAITING B] Waste of MOVEMENT C] Waste of TRANSPIRATION D] Waste of PROCESSING or OPERATION
  30. 30. World class Overproduction Worst class
  31. 31. 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
  32. 32. 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. 33. 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
  34. 34. 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
  35. 35. 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
  36. 36. 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. 37. 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. 38. 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
  39. 39. 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.
  40. 40. 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.
  41. 41. 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. 42. 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
  43. 43. 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
  44. 44. 4. Waiting Waiting time should minimized by Multi-process operations Waiting for tools can be eliminated by delivering tools on line ( on Machine )
  45. 45. 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
  46. 46. 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
  47. 47. 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
  48. 48. 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
  49. 49. 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. 50. 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
  51. 51. 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
  52. 52. 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
  53. 53. 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. 54. 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
  55. 55. 7. Defects/ Production of Inferior Goods Process produces defectives which either to be reworked or scrapped
  56. 56. 7. Defects/ Production of Inferior Goods This must be reduced / eliminated by process improvement , making processes more capable. ACHIEVE ZERO DEFECT at EACH STAGE
  57. 57. Non- Value Added / Waste Unevenness / Inconsistency / Imbalance Overburden / Strain
  58. 58. 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
  59. 59. Non- Value Added / Waste Unevenness / Inconsistency / Imbalance Overburden / Strain
  60. 60. Unevenness / Inconsistency / Imbalance Two things / activities are having large variation result in losses. This can be reduced by balancing or reducing Variation
  61. 61. Unevenness / Inconsistency / Imbalance Few 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
  62. 62. Non- Value Added / Waste Unevenness / Inconsistency / Imbalance Overburden / Strain
  63. 63. Non- Value Added / Waste Unevenness / Inconsistency / Imbalance Overburden / Strain
  64. 64. 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
  65. 65. Unevenness / Inconsistency / Imbalance Few 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
  66. 66. 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

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