Your manufacturing operations are creating too much waste. What can you do to reduce it?

Identify WASTE under COMMWIT 7 WASTES and take action to reduce it. Make a CI plan, with periodic reviews and decide set of action with responsibility and timelines.

Waste in manufacturing refers to activities that consume resources but do not add value for customers. These can include defects, overproduction, waiting, underutilized talent, transportation, excess inventory, unnecessary motion, and extra processing. Identifying and eliminating these wastes through Lean Manufacturing principles is key to improving efficiency and reducing costs.

The first principle in Lean Methodology is the removal of waste within a system. And in any business, one of the biggest drains on profitability is WASTE. In Lean Manufacturing, waste is any expense or effort that is expended but which does not add to the value the customer is willing to pay for. Lean waste can come in the form of time, material, labour and utilization of talent/skills. Commonly Lean Methodology uses the acronyms TIMWOOD or DOWNTIME to define waste. D: Defects O: Overproduction W: Waiting N: Non-utilized talent T: Transportation I: Inventory M: Motion E: Extra-processing Lean Methodologies are built on the basis of systematic ways to identify the above waste and reduce or eliminate them within the system.

Sugiro a implementação de um programa abrangente de Melhoria Contínua. Comece identificando as fontes de desperdício por meio de análises detalhadas, como a utilização da metodologia dos 5S para organização e eliminação de itens desnecessários nos locais de trabalho. Em seguida, utilize o Mapeamento do Fluxo de Valor (VSM) para identificar e eliminar atividades que não agregam valor ao produto final. Implemente também o Sistema Kanban para otimizar o fluxo de produção e reduzir o excesso de estoque. Além disso, promova uma cultura de engajamento dos colaboradores, incentivando a sugestão de melhorias e o envolvimento em projetos de redução de desperdício. Por fim, monitore continuamente os resultados e ajuste as estratégias.

Reduce waste by simplifying processes and minimizing excess inventory, train employees, recycle, and collaborate with suppliers. invest in energy efficient tech, follow regulations, and embrace continuous improvement for sustainable manufacturing efficiency.

Implementing systems where work is pulled based on actual demand rather than pushed through the system, helps to prevent overproduction. We should also focus on maintaining and improving equipment reliability to reduce downtime and waste.

The most common and obvious way to identify wastes is through engaging in 'Gemba Walk'. Gemba means real place where work is carried out. A careful walk by the concerned members around the Gemba will reveal a lot wastes- defective parts lying on floor; stacked materials waiting to be processed in front of machines; operators waiting for materials, tools or instructions; unnecessary movement of people due to poor lay out; excess inventory of raw materials/parts not being used are all classic examples of wastes those can be uncovered. In TPM, Initial Cleaning step may help in identifying wastes pertaining to Equipment. Apart from these, PFD and VSM may provide Analytical Insights in spotting waste in terms of NVA, Waiting time, Lead time.

Value Stream Mapping and the 5 Why are great tools to use, but you must also walk the floor and see the process first-hand, to identify opportunities for waste reduction. GEMBA is important, go to the where the value is created.

Stand up into an operation and look closely at it for 15 minutes. If you are able to find at least 10 different wastes you are looking at the process the right way and if you can't you need to look closely because you are not seeing them. Another way to identify waste is to look for anything that adding cost to your operations that is not adding value to the product. You could also step into the process and do it yourself to see if you can find ways to improve the process and therefore reduce the waste at that station.

Simply taking a walk around the production floor will give you 80% of the answers. If you know the 8 typical types of waste, pick one to focus on and observe the shop floor looking for that waste. What you focus on, you will find! The results may surprise you.

To quote a great leader I once worked for "what doesn't get measured doesn't get done". If you want to eliminate waste, there needs to be a method to measure, set a target and evaluate the improvements against those targets.

To reduce manufacturing waste, implement Lean Manufacturing principles, emphasizing continuous improvement and waste elimination. Conduct a thorough waste audit to identify and quantify sources of waste. Implement efficient production processes, adopt just-in-time inventory systems, and invest in employee training for waste reduction. Engage employees in waste reduction initiatives, encourage recycling, and explore innovative technologies for sustainable practices. Regularly monitor and reassess the waste reduction strategies to ensure ongoing improvements in operational efficiency and environmental sustainability.

Once wastes are identified, we shall focus on eliminating or at least reducing them. In Lean Manufacturing there are a number of proven and time tested methodologies which are very effective in dealing with the problems of waste. A few of them are: 5S: The most fundamental methodology in Lean involving people in organizing the work place for improved productivity, Quality, safety and Morale. VSM: A visual and Analytical tool to delve deep into wastes within the processes. Kanban: Helps improving inventory management and reduces waiting time. Standard work: Standardizes each element of work. Poka-yoke: Eliminates or reduces the probability of defects occurring in the process. SMED: Reduces or eliminates set-up change over time.

I have learned that engineered solutions are stronger controls, when compared to training, signs, or general conversation. A system that will not let a defect occur is a strong system. What I have seen, often in my career is that teams form comples engineered solutions, without understanding the problem. Taking the time to define and understand is very important before jumping to solution mode.

Establish closed-loop systems where waste from one part of the manufacturing process becomes a resource for another. This promotes a circular economy.

Para que haja a continuidade de reduzir o desperdício precisamos ter em toda a organização uma cultura "enraizado" em cada colaborador e em todos os níveis da organização. Todos devem entender que essa cultura de reduzir desperdício e para manter a sustentabilidade e sobrevivência da organização, ela sendo financeira ou em questão ambiental, pois para gerar o desperdício foi utilizado os recursos como matéria prima, água, energia elétrica, etc... Está jornada não deve ser empurrada , mas deve ser agarrado por todos para ser solucionado. Pois todos engajados para a resolução dos desperdício os resultados viram mais rápido.

In my experience, the following may be done to sustain waste reduction: 1. Create a structure: Create a Lean Organization structure with right people, adopt appropriate technology, systems and processes, train people. 2. Nurture a thriving infrastructure: Encourage people to exploit the structure, create a culture of learning and innovation. 3. Provide dynamic leadership. 4. Define KPIs and metrices: There shall be defined KPIs and matrices to capture the Lean performance and actions plan shall be in place to achieve the goals as well as to bridge the gap if any. 5. Regular audits and reviews: Appraise the waste reduction performance through systematic and structured audits and reviews. Apply PDCA for a spiraling continuous improvement.

A forma mais eficaz de sustentar a redução de resíduos é através da padronização do uso e do descarte dos materiais. Para efeitos de legislação brasileira, existe o Levantamento de Aspectos e Impactos Ambientais, que também deve ser atualizado a cada melhoria feita para redução e eliminação deo resíduo.

Leadership Team should promote a culture of continuous improvement and waste reduction throughout the organization. Organizations should encourage and empower employees to actively participate in waste management initiatives. Organizations should establish a feedback mechanism for employees to share improvement ideas and report issues related to waste. Organizations should celebrate achievements and successes in waste reduction. Organizations should recognize teams and individuals for their contributions, fostering a positive and rewarding environment for continuous improvement. Organizations should continuously seek opportunities for benchmarking and learning from best practices in waste management.

Eliminating or reducing waste from your operation will never end. There is always going to be faster, cheaper, safer and more efficient ways of doing things. Gather data and create KPI's so you are able to measure your effectiveness. Monitor KPI's and get your employees involved in change. When you get input and influence from the people doing the work, the buy in and sustainment comes much easier. The end goal should be zero waste, so there is always something to work towards, but set smaller achievable goals along the way. Celebrate the wins to keep people motivated!

To reduce waste in any process, One Of the key principles is Common sense. Lean Manufacturing and Six sigma etc are nothing without Common sense and eagerness to improve.

Incorporate lean manufacturing principles like the 5S methodology and continuous improvement techniques to identify and eliminate wastage throughout the production process. Continuously monitor and measure the progress of waste reduction efforts. Set achievable targets for reducing waste and regularly review performance to identify areas for further improvement.

Start with a low effort waste reduction project and use that as a stepping stone for the organization to realize and come to know of what waste is all about. Use this small project to trigger a step change in the organization culture and inspire more waste reduction projects to start get-going.

In my experience, addressing excessive waste in manufacturing operations requires a multifaceted approach centered around operational excellence. Firstly, implementing tools and methodologies for designing, monitoring, and controlling processes efficiently is crucial. This involves adopting lean principles, Six Sigma methodologies, and advanced process control techniques to identify inefficiencies and optimize workflows. Additionally, empowering a culture of operational excellence among employees is essential. This entails instilling a mindset of continuous improvement and empowering individuals at all levels to actively contribute to waste reduction efforts.

“People are the most important resource. Technology moves on, hardware gets outdated, but people who work in business are what moves that business forward.” Sir John Harvey-Jones