Overproduction means
“Producing
the products in excess quantity which are not required for next operation or
Customer.”
Over production waste occurs when we manufacture, assemble, or build more than what is needed. We make some thin just in case instead of Just in time (JIT). In accurate scheduling, long lead times, long changeovers and not being close enough to our customers to understand there changing needs leads us to longer production runs. We worry that our customer might need more while we must suffer with the associated cost of unsold goods or services.
Look for processes producing more than is being “pulled” by the customer and requiring storage between processes.
Reduce by improving change over and set up times and balancing production lines.
Overproduction increases Money spend for:
- Energy
- Record keeping
- Documentation
- Tooling Cost
- Manpower cost
- Overheads
- Space for Storage
- Inventory cost(Reduction in
Inventory Turns ) This is hidden money.
Why ? Overproduction
1. No confidence in process
2. No confidence on set-up
Quality
3. No confidence on equipment
4. No confidence on people (Operator.
Availability)
5. Meaningless increasing
efficiency
6. Available = Make Use ….
Concept followed.
How to avoid Overproduction
1. Do not produce more than next process demand
2. Build confidence in process,
set-up
3. Improve m/c condition
4. Improve attendance / multi-skilling
Indirect ways of reducing over-production
1. Reduce Finish Goods area
2. Reduce space between two
operations
3. Implement 100 % 2 S
Management’s role:-
• Communicate to all for following the concept... Produce when next process demands.
• Decide WIP norms and FG Norms.
Overproduction results in
a) Increasing rejection, scrap
b] Reducing CASH-FLOW
c] More searching and sorting
d] BAD 5 S
e] Moving Company towards
opposite direction of world Class
Overproduction HIDES
A] Waste of WAITING
B] Waste of MOVEMENT
C] Waste of TRANSPIRATION
D] Waste of PROCESSING or
OPERATION
Wastes of Defects / Rework
Defect / rework waste happens
when we do not have robust preventive system that include Poka-Yoke and mistake
proofing techniques. When we cause an error or defect and pass it on to the
next operation, or worse, we pass it to the customer; we are accepting rework
as part of the process. We lose money when something is manufactured, assembled,
or serviced twice. While our customer will only pay us once for the goods or
services.
Look for defective, partial, or un-completed products or services and completed units that are reworked or thrown away.
Reduce by improving visual controls and initiating more complete Standard operations procedures. Implement mistake proofing or Poka – Yokes at the source or the place errors occur.
Process produces defectives which either to be reworked or scrapped.
This must be reduced / eliminated by process improvement, making processes more capable.
ACHIEVE ZERO DEFECT at EACH
STAGE
Waste of Motion
Motion waste is the unnecessary movement of people, product or equipment that adds no value to a process. Workers walk back and forth from the work are to supply, around unneeded equipment or perform redundant motions that can be eliminated to speed up a process.
This can be one of the most frustrating
wastes for workers and management. The lost time and production rob most
processes of opportunity to function efficiently and make the employees work
harder. While most processes are not designed to have motion wastes in them, it
is one of the first wastes to creep in and cause disruption.
Look for excessive walking, moving, or handling and prepare a
complex diagramme of actual process flow.
While operating a machine or performing any activity on shopfloor,
some of movements / motions of operator does not add value.
This can be reduced by carefully studying every movement / motion
of operator and standardizing each activity.
I.e., loading place / unloading / lifting place.
Wastes of
Transportation
Conveyance is caused by long distance between two machines / two
locations.
This increases material handling and waste of manpower and chances
of damages of products.
Waste of Conveyance can be reduced by Improvement in Layout,
eliminating temporary storage methods which need again conveyance of material
to final location.
Transportation waste occurs when people, product, equipment, or information are moved more often or further than needed. During multi step processes materials and people are moved from process to process that are separated by distance and / or time.
Instead of processes being sequential or
positioned next to each other, they are far apart and require forklifts, conveyors,
or other moving devices to be repositioned for the next step in a process. All
this movement adds no value to the process.
Look for movement of people, material or information that does not
add value to a process.
Reduce by minimizing the physical distance the material and / or
transportation travel with zoning and new layouts.
02. why-implement-total-productive
03. what-is-tpm
04. 12-steps-for-tpm-implementation
05. typical-tpm-organizational-chart
06. effectiveness-of-tpm
07. 5-principles-in-tpm-development
08. purpose-and-main-activities-of-kk
09. purpose-and-activities-of-jh-pillar
10. purpose-activity-of-pm-pillar
11. purpose-activities-of-qm-pillar
12. purpose-and-activity-of-dm-pillar
13. purpose-and-activity-of-otpm-pillar
14. purpose-and-activity-of-e-pillar
15. purpose-and-activity-of-she-pillar
16. company-wide-tpm
17. jishu-hozen-information
18. ishu-hozen-equipment-deterioration
19. role-of-production-maintenance-in-jh
20. jishu-hozen-step-1
21. 1s-2s-implementation
22. jh-step-01-abnormalities
23. exposing-seven-types-of-abnormality
24. 2-unfulfilled-basic-condition
25. 3inaccessible-places
26. 4-contamination-sources
27. 5-quality-defect-sources
28. 6-unnecessary-non-urgent-items
29. 7-unsafe-places
30. jishu-hozen-step2
31. jishu-hozen-step-3
32. one-point-lesson-opl
33. visual-control-visual-management
34. 35. what-is-smed
36. why-energy-conservation
37. mobile-phone-handling-important-tips
38. kaizen-way-of-life
39. what-is-kaizen
40. techniques-used-in-kaizen
41. tmv-mba-project-guideline
42. gdmm-project-guidelines
43. importance-of-energy-conservation
44. global-warming-25-tips
45. latest-abcd-from-nursery-school
46. world-environment-day-5th-june
47. be-proud-to-be-engineer-happy
47. lean-tools-hidden-waste
