Zero Loss Manufacturing
Zero Loss Vision
Manufacturing Industries are subject to different kinds of losses, “Zero Loss” is an aim/attempt to overcome such losses or minimize their effect up to a great extent in order to reduce the manufacturing cost. Manpower Rationalization is one such way to achieve the goal of zero loss. It relies on the reorganization of a company to ensure a more effective structure. It refers to the discharge of an employee with the removal of the job position itself. The strategy helps in sizable cost saving as some jobs become redundant after a time while others can complete the same tasks efficiently, at lower costs.
Manufacturing Cost Reduction Activities
1) Reduce The Ever-increasing Manufacturing Cost
2) Improving The Line Efficiency
3) Cost Associated With Poor Quality of Product
Tools & Techniques
- Design Failure Mode Effect Analysis (DFMEA) helps to reduce the overall costs of design failure. Ideally, these failures are identified early, ensuring the finished products are free from problems when they hit the market. When Design FMEA is effective, you can reduce expensive consequences, such as product recalls, or even lawsuits from consumer tragedies.
- Advanced Product Quality Planning (APQP) process is cross-functional, so teams can work together to design a product that meets the customer requirements and is manufacturable with minimal cost and labour. This will reduce the overall lifecycle costs of designing, manufacturing, and supporting a product.
- Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and no absorption of fixed cost the overall objective is to match the production rate after all wastes have been removed to the Takt time at each process of the value stream.