Blog Post Different Wastes That Are Eliminated By Lean Manufacturing

Different Wastes That Are Eliminated By Lean Manufacturing
Nov

7

2014

Different Wastes That Are Eliminated By Lean Manufacturing

The concept of lean manufacturing was developed only after the recognition of wastes in the manufacturing process that cause a loss of money and material resources. Unfortunately, there are no set of instructions, and every practitioner has to make the process more efficient and less wasteful with his own creativity. What is almost same everywhere is kind of wastes that are present, which are also discussed below-

Lean finds its origin in the Japanese manufacturing industry, and is a process that aims to reduce any wastage during manufacturing and maximize productivity.

This is only possible once the areas that produce wastage have been recognized. These wastages could possibly take the following forms –

Overproduction

Overproduction may be the result of two possibilities –

  • Producing extra in order to satisfy customer orders in time
  • Producing extra to benefit from economies of scale

One may use shop lean implementation to control wastes in job shops. It is very much possible to produce small batches economically, and also helps in avoid the necessity of producing extra units.

Faulty Factory Layouts

Factory layouts can be responsible for excess transportation. You need to plan a layout that allows minimizing wastage and reduces time of transportation. Lean manufacturing jobs in Calgary will particularly ask for such skills from applicants, who seek to make a profession in lean manufacturing.

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Excess Inventory

Most of the times an excess in the inventory is due to defects in the quality, which one has to compensate for. By implementing strict quality control measures along the production process, this waste can be minimized, and you can also implement lean manufacturing for the same.

Motivation

Motivated employees are always more productive than a bunch of frustrated people. Understanding employee problems and resolving them in time is therefore essential.

Untidy Work Space

Working in filthy places, cramped constructions and dark and dingy moats where ventilation is a luxury also contributes in reduced efficiency. Contrary to that, when companies concentrate on tidying up the work space and arrange all the materials systematically, and dispose of unnecessary things that create a clutter will enhance efficiency manifold.

Rework On Defective Units

It is very important to find the exact quantity of defective pieces being produced in every batch. Once you can make a sequence of the number of defectives in every batch, try and find out ways to reduce this wastage, maybe by employing better machines, making employees and workers more responsible, etc.

Delays

So many times, products keep waiting in factories, sometimes, raw materials or unfinished goods pile up in corners, which may eventually turn into a big waste. When large batches are produced, there are more chances of over production. The only way out is the keep the bottle neck processes going, if you want delays to cause minimal wastage.

Wastage of Energy

You may not realize but poor usage of energy forms results in more expenses, which ultimately translates into lost money.

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