| Topic : Green Production Methods in India |
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Manufacturing & Engineering Professionals |
Automation |
Production and Mechanical Engineering |
4 more ...
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Activity:
684 views;
last activity : 03 14 2011 12:04:20 +0000
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Identify and eliinate delays in production
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Employee involvement
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Eliminate waste at Planning stage first
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Quantification of waste is the first step
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Following FMEA and TQ process.
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Identify and eleminate wastes
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Identification of Root Cause
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use cloth napkins only
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identify the nature first then ....
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keep eliminating the waste in entire prosess right from planning to dispatch
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Need a complete strategy
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Depends on the type of waste
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Take realestic action
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Minimum Rejection rate and Waste reduction tips
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Overall waste in Production
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Eliminate Waste in the production process
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Just-In-Time
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first thing is to identify waste. any activity which is not adding value is a waste.
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Eliminate waste at Planning stage first.
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Recycling is the best way of reducing waste.
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Identify and eliminate the delays in production process. Concentrate all efforts to optimize "Through-put time". The production delays means- a. providing reasons for in-process rejection and wastage. b.increase in production inventory cost. The delays can be brought to Zero, by optimum production planning, line balancing and effective Preventive & predictive maintenance practices. |
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avoid paper work which are of no use.bring only those things to paper which are compulsultions.use only required size papers instead of show of
FIRST LIST OUT THE REASONS FOR WASTE CREATION. ANALYSE THE REASONS AND FIND OUT THE SOLUTION , THE SOLUTION CAN BE IMPLEMENTED IN THE PROCESS AS MISTAKE PROOFING AND AWARENESS TO CREATE WITH THE CONCERNED OPERATOR
Mr. Dixit,
Your response is very apt and correct on this subject
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Waste in the production process may be inevitable as the result of activities or environmental conditions that prevent a team from reaching its goal. |
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yes isha u spotted well, now a day in manufacturing setup pressure is on cost cutting & margin are very low. So controlling of waste is margin. How much we control waste we increase our margin percentage.
Yes, Before elimination of the waste, we need to change the culture of the employee. In my company we started cleaning the shop floor and machine all the employees. When i said all the employee means no matter employee is in what position. The resistance of accepting will be more in the begining, later after two months everybody will start accepted the culture. Better everybody should go through "Toyata Way of Life" book.
hello Isha, waste may not become inevitable if the process flow parameters are in place.eventhough all process starts from planning and ends with finish by human involvement, there needs a regular and systematic checks between the process.proper VSD/VSM will control any process and give some light regarding eliminating wastes.wastes can also be direct / indirect, first it is better to avoid direct waste for eg.repetative internal defects.process wastes will develop gradually through out the value stream and it has to eliminated in the same way of its development! in my experiance, reverse process also helps in eliminating waste some times.once waste elimination is minimised the same has to be put in system right from control plan and relatively linked documents in process flow.any process which has direct human influence in process, waste can't be eliminated instead it can be minimised.
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We have to first identify the fat in the entire process, Good Planning and quality oriented philosophy and working with given weightage to standards and safety are the ways to remove the waste. But the initiation of the waste starts from the planning so it has to be given the prime importance. This is the area which is often overlooked or taken casually due to the taget deadlines, costs etc. A wate once added acts as a nucleus to generate even more waste.
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Use 3P while settingup production line. It will ensure implimentation of previous learnings and ensure major portion of waste is eliminated
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If we are talking of Toyota's 7 types of waste, Work sampling ( 100 observations as per Japanese practice) is the best starting point for quantifying waste of Manpower, effort, delay etc. WS can throw up interesting facts. As far as waste of material is concerned, Material Balancing, material Accounting, Scrap analysis etc would be useful. |
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bhagwatgita had identified the importance of waste management..it advotaces lovemaking only for pocreation.how many people follow it.
so theories would be always theories law in practice and law in books is different.
how many women/men would agree there should not be delay in production.
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The FMEA will give you where and how and what is needed to be avoiding wastage , time or more work. And TQM will definitely involve man , machine and interface communication needed in PM department.
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First define waste in your process as per requirements of the customer. Also Keep in mind that more than 85% of wastes are due to process and not humans. After defining the wastes. Study in detail the process that is generating that waste. Try to analyze why is the process giving out the wastes using the ISHIKAWA analysis chart or the fish bone diagram taking into consideration factors like measurement, People, Process, Material, Equipment, Environment and asking why why questions to every parameter and finally each why answer will lead you to the root cause of production of waste. So finally when you understand the cause of waste and effect of waste you can design the corrective and preventive action for the waste. Also you can use 5S concept in process, that also can help you in prevention of wastes Hope my view is useful to you. |
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Mr.Sumit has given a very nice idea. Its true that more than 85% of wastes are due to process and not humans. When we understand the proper source of generation of wastes, it will be very easy to prevent them.
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I think identification of root cause might be the first step to eleminate the waste in production processes. In my view the following are some of the basic root causes of wastes. 1. Improper training to the operators. 2. Delay in the process. 3. Non Conformance input (Raw Material) to the process. 4. Recycling the waste. By troulbeshooting the above things, we can eleminate the waste.
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these can be reused
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First u have to identify the nature of the waste , then try to adopt necessary counter measures , as per lean system watages can be catogarise into several like time , inventory .....
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brain storm for the consumption of material and time.these are the main factors to be considered while identifying and elimiating the waste in production.Then analayse the reports for what to be and what actually happenning.Defferentiate the value and nan value activities in the processing of the product.just try to minimise the non value activities for the product.It impacts directly in material and time. |
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To minimise waste in the process we need to devise a complete roadmap from identification to its elimination. We should also understand that wastes are both visible and invisible.We can follow following steps to identify and work towards its elimination:-
1. Involve people to brainstorm and identify every type of wastes. This can be made a routine process by forming a "Waste Minimisation Cell" and periodicity of meetings be pre- defined.
2.the ideas generated in these meetings be submitted with details of action plan like cost involvment, likely time for completion and possible savings.
3. On concurrence from top management implement the action plan in shortest possible time.
4.Data mapping prior and after implementation is of utmost importance for motivation of people involved and top management.
5. Share the results with the cell and mgt. for rewards/ appreciation
6. Repeat the process for next project.
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It totally depends on the type of waste.
Like if it is a waste water or air then efforts should never be made to mitigate it during the production if doing so is affecting the production.
Because there are sectors which totally operates on waste and treatment of them.
Rather than focussing to lessen them while in production it is far better to have a separate waste treatment plant for the same.
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operater negligencey , lack of process
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a) Procure right Raw mtl. b) Inspect to conform technical specification to segrigate defective mtl. before taking up for further production . c) Strictly adhere to Process sheets. d) Use right machines. e) Deploy experieced operators. f) Use appropriate cutting toos/ Jigs/Fixtures etc. g) Implement optimum cutting parameters recommended for the operation h) Carry out Ist. off inspection for the Ist. component before finishing remaining batch quantity. i) Review the process/method and complete the remaining batch quantity maintainig specifications as per Engg. Dwg. |
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Eliminating waste from the Production Process: There are Different types of Waste in any Production/Manufacturing Process: 1. Raw material Waste: can be minimized by application of simple JIT( Just In Time) System and Quality checks at Suppliers End. 2. Storage Waste: Can be minimized by proper Storage of Raw Material, FIFO and LIFO Systems 3.Transportation Waste: Can be minimized by perfect design and selection of Material Handling Equipments, Proper Machine & Plant Layouts, Using Gravitational Flows wherever applicable etc.. depends on Material to material.... 4. Process Waste: Process Waste can be minimised by Reducing Contact of Material with work persons, Automation & Autonomation of Process, Propoer Plant Layout, Machine Layouts etc.... 5. Quality Waste: This can be reduced by online Quality checks Instead of Storing and Checking the Quality 6. Finished Product Waste: This can be reduced by Propoer Storage of Finished Products, Minimum Handling, Using Conveying systems, propoer Identification and marking systems etc... 7. All these waste and therfore cost can be minimised with proper Production Planning so that any material/Finished product will not lay in factory premises for longer duration than the Cycle & selected Storage time. Beside these Wastes there are also Man Hours waste, Reworking waste as well time waste that one shud always consider while focussing on REDUCTION of Wastes. Proper Man Power Training also plays vital role in reduction of waste. |
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dear isha gi YOU ALSO MENTIONED SAME IDEA which has been we were follow it |
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Plan your production in such a way that yield minimum waste (this may increase your project duration). Use JIT (Just-In-Time) Production technique. |
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define types of waste. Identify waste and try to eliminate waste |
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Wastages are to be made optimum by motivation of team and with proper co-ordination at correct time. Think of universe rather than our profits. |
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Gouri Shankar Patnaik, General Manager Quality Control, Bindal Papers Limited
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