What are the main causes of operational waste?

Waste comes from inefficiency in various areas - inefficiency in the process , inefficiency in the people , and inefficiency in the raw materials.

For instance , if the thickness gauge which is used to control the thickness of the product , say paper or steel , is not functioning properly , then the material coming out of the process may be substandard.

If the people operating a particular machine are inefficient , and let us say do not setup the machine properly , then the product from the machine may be scrap.

If the input raw material into a process is not inspected properly , and is not in conformity with the standard , then the output may also be non-conforming - GIGO.

Over production is a common but very serious isuues. If situations are good then the surplus stocks get sold or is moved away form the ware house. But if are unlucky then you have to bear the burden of unnecessary loss.

The concept of Heijunka needs to be applied to all functional areas & not only manufacturing. It starts from customer enquiry, Order Forecasts till Revenue realization. In brief the whole SCM. All other points that are in the discussion get covered by this single one act.

-Harish Patel

Proper Planning of 4 M i.e man,material,machinery & money is most important for reducing the wastage.Good planning is important as material cutting,  proper distribution of work can reduce wastage work hour machining hour & of course money.Execution of plan according to requirement is always not possible but if implemented properly can reduce wastage upto some extent.

MACHINES ARE MEANT FOR PRODUCTION.HEALTH OF THE MACHINE IS A FACTOR NEGLECTED BY ALL.ROUTINE HEALTH CHECK KEEPS THE MACHINE FIT AND THERE IS NO PRODUCT PILE UP, WHICH IS ACTUALLY A WASTE AT ANY STAGE IN THE PROCESS.

Main types of wastes & their causes are:

1. Overproduction

Causes: Just-in-case logic, Fear of running out, misuse of automation, long process setup, un-level scheduling, unbalanced workload.

2. Stock

Causes: Maintaining excess inventory, supplies, work in process (WIP), or finished goods in order to compensate for process inaccuracy, need for buffer against inefficiencies and unexpected problems, product complexity, unlevelled scheduling, poor market forecast, unbalanced workload, misunderstood communications, unreliable shipments by suppliers.

3. Production of inferior quality goods

Causes: Weak process control, poor quality, unbalanced inventory level, deficient planned maintenance, inadequate education, training, or work instructions; product design; customer needs not understood.

4. Unnecessary movement of worker

Causes: Operators making movements that are straining or unnecessary, such as looking for parts, tools, documents, etc. not focusing on ergonomic design. Any wasted motion to pick up parts or stack parts. Any wasted walking or moving around. Wasting time looking for things in a cluttered work space or desk. Poor effectiveness of people & machines, inconsistent work methods, unfavourable facility or cell layout, poor workplace and housekeeping, superfluous movements while waiting.

5. Overprocessing / unneeded operations

Causes: Product changes without process changes, true customer requirements not clearly defined, over processing to accommodate downtime, lack of communication, redundant approvals, extra copies or excessive information, using more expensive equipment or tools where simpler ones would suffice. Having meetings or people at meetings that are not needed. Preparing duplicate records is also over processing.

6. Unnecessary transportation of Material

Causes: Poor plant layout, poor understanding of the process flow for production, large batch sizes, long lead times and large storage areas.  

7. Delays due to waiting

Causes: Waiting for a part, instructions, materials or information required to perform work or make decisions because of having non-aligned objectives, unbalanced workload, unplanned maintenance, long process setup times, misuse of automation, upstream quality problems, un-level scheduling, poor material flow, production runs are too long, and distances between work centers are too great.

8. Assigning work not according to the competence of the person

Waste or MUDA control is the only way to obtain higher efficiencies. Mostly it arises out of non adherence to prescribed norms or Processes. While sub standard product is accepted it only reflets non conformance.

If we can tune in people process and material to norms then operational efficiency will not suffer

Every member should have clear idea about the Processes. the machines and equipments and should have awareness to understand the need to adhere to the set norms. For this proper periodic refresher training is necessary.

Review processes to evolve better methods, review of strict upkeep of equipments (many production managers are unable resist the temptation to increase today's production, by avoiding maintenance or overloading machines, at the cost of future performance of the Organisation).

Collectively Analyse the reason for fall in quality and methods for improving Quality.

Irresponsiblity at all the levels of production..is the main cause........n this cause at higher levels causes mismanagement..which leads to waste....operational waste....