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Your manufacturing operations are producing too much waste. How can you reduce it?

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Waste reduction is a key goal for any manufacturing operation, as it can save money, improve quality, and protect the environment. However, achieving it can be challenging, as it requires a systematic approach to identify, measure, and eliminate waste sources. In this article, we will share some practical tips and products that can help you reduce waste in your manufacturing operations.

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Alex Krutz

Manufacturing & Supply Chain Advisor | Value Creation Specialist | #Thefactorydoctor

1 Define waste

The first step to reduce waste is to define what it is and how it affects your operations. Waste can be any activity or resource that does not add value to your customers or products, such as defects, overproduction, waiting, inventory, motion, transportation, or over-processing. You can use tools like the 8 Wastes of Lean or the 7 Wastes of Six Sigma to classify and analyze your waste types.

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Arul Selvan

Business Process Consultant
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Substance or object that is no longer useful for the rest of the business process, with the result that the enterprise wants to or has to dispose of the waste.

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Angel Free
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Some ways to get started: -Reverse engineer your manufacturing process. -Lower your inventory levels. -Look for friction. -Ask your employees what frustrates them the most.

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Magdy Nasr

Sales & Marketing Director -Middle East
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You to identify the wast and check if its within the acceptable % of the production plan and try to reduce it if its possible to increase productivity and reduce waste.

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2 Assess waste

The next step is to assess how much waste you are generating and where it is coming from. You can use methods like value stream mapping, process flow diagrams, or waste audits to visualize and quantify your waste streams. You can also use indicators like the overall equipment effectiveness (OEE), the inventory turnover ratio (ITR), or the first pass yield (FPY) to measure your waste performance.

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Alex Krutz

Manufacturing & Supply Chain Advisor | Value Creation Specialist | #Thefactorydoctor
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Assessing waste in any production process is key. A good strategy of this is through the GEMBA process and daily walks through the shop. Pairing this communication process with the team and reviewing the operations metrics, identifying waste should become part of the process.

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3 Eliminate waste

The third step is to eliminate or minimize the waste sources that you have identified and assessed. You can use techniques like the 5S system, the Kaizen approach, or the Poka-Yoke method to improve your workplace organization, process efficiency, and error prevention. You can also use products like lean manufacturing software, waste management systems, or recycling equipment to automate and optimize your waste reduction.

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Alex Krutz

Manufacturing & Supply Chain Advisor | Value Creation Specialist | #Thefactorydoctor
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Goldblatt's theory of constraints is an excellent method of identifying waste. Simply stated, you look for areas to that have high inventory, high costs and low productivity. The theory states to lower inventory, lower costs and improve output. If you focus on these three areas of the operation, the waste in the process will become very clear.

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4 Monitor waste

The fourth step is to monitor your waste reduction results and ensure that they are sustained and improved over time. You can use tools like the Plan-Do-Check-Act (PDCA) cycle, the balanced scorecard, or the KPI dashboard to track and evaluate your waste reduction goals and actions. You can also use feedback mechanisms like the employee suggestion box, the customer satisfaction survey, or the ISO 14001 certification to collect and implement waste reduction ideas.

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Alex Krutz

Manufacturing & Supply Chain Advisor | Value Creation Specialist | #Thefactorydoctor
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The PDCA cycle works very well. Another method is through daily logs available to the entire operation to freely update on a Actions, Owners and Dates log. This should be a communication method for all employees and to freely add to it what the necessary action is, who owns it and what date it should be accomplished for the waste reduction.

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5 Educate waste

The fifth step is to educate your employees, suppliers, and customers about the importance and benefits of waste reduction. You can use methods like the lean training, the green procurement, or the eco-labeling to raise awareness and skills on waste reduction practices and principles. You can also use incentives like the reward system, the recognition program, or the environmental report to motivate and engage your stakeholders on waste reduction.

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6 Innovate waste

The sixth and final step is to innovate your products, processes, and business models to create new opportunities for waste reduction. You can use approaches like the design thinking, the circular economy, or the cradle-to-cradle concept to rethink and redesign your value creation and delivery from a waste reduction perspective. You can also use products like the 3D printing, the biodegradable packaging, or the renewable energy to reduce your material and energy consumption and waste.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Your manufacturing operations are producing too much waste. How can you reduce it?

1

2

3

4

5

6

7

1 Define waste

2 Assess waste

3 Eliminate waste

4 Monitor waste

5 Educate waste

6 Innovate waste

7 Here’s what else to consider

Manufacturing Operations

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Your manufacturing operations are producing too much waste. How can you reduce it?

1

2

3

4

5

6

7

1 Define waste

2 Assess waste

3 Eliminate waste

4 Monitor waste

5 Educate waste

6 Innovate waste

7 Here’s what else to consider

Manufacturing Operations

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感谢您的反馈

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