ZERO LOSS MANUFACTURING

Reduce increasing manufacturing cost

Improving the line efficiency

Cost assoc. with poor quality of product

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

reduce the ever increasing manufacturing cost

1) Reduce the ever-increasing manufacturing cost

improving the line efficiency

2) Improving the line efficiency

cost asociated with poor quality of product

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 labor. 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.

MANUFACTURING EXCELLENCE IMPLEMENTATION PROCESS

OBJECTIVE : 

zero loss

Zero Loss: Zero Loss” is an aim/attempt to overcome such losses or minimize their effect up to great extent in order to reduce the manufacturing cost

EXAMPLES

  • Advance Lean Practices Implementation
  • Manpower Rationalization
  • Design & Process FMEA
  • APQP
  • Line Balancing

OBJECTIVE : 

employee engagement

Employee Engagement: To improve workplace conditions that drive engagement and enhance employee sense of well being.

EXAMPLES

  • Basic 5S Awareness
  • 1S, 2S Implementation
  • Workplace Visual Management (Visual Factory)
  • Kaizen Strategy Implementation
  • Suggestion Scheme
  • Innovative Leaders

    OBJECTIVE : 

    zero breakdown

    Zero Breakdown: Maintenance is all about working for the ultimate goal with a winning maintenance strategy.

    EXAMPLES

    • My Machine Campaign
    • CLIT
    • Machine Utilization Monitoring
    • Machine Losses Reduction
    • Breakdown Analysis
    • Preventive Maintenance
    • 3S ,4S & 5S for Machine & Office area

    OBJECTIVE : 

    zero waste

    Zero Waste: To eliminate waste across entire waste value chains to the fullest extent possible through reuse and recycling. Zero Waste is more than just a problem of disposal but a need to reduce harm encompassing the entire life cycle of a product.

    EXAMPLES

    • Time & Motion Study
    • Lean Layouting
    • ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)
    • Material Handling Optimization
    • OEE/ OLE

    OBJECTIVE : 

    zero accidents

    Zero Accident: The risk of falling, risks related to electricity or handling of machinery, road hazards, and more. Every day, the awareness of each and every employee is essential to avoid accidents in the workplace and to prevent occupational illnesses.

    EXAMPLES

    • OH & S Management System Implementation
    • Safety KPIs
    • Workplace & Safety
    • HIRA
    • Safety Signage Standardization

    OBJECTIVE : 

    zero Fatigue

    Zero Fatigue: Fatigue is a workplace hazard and can be associated with the safety and health of the worker. It affects the health and safety of the employee.

    EXAMPLES

    • Scope Defining
    • Workplace Ergonomics Analysis different Technical Score (REBA, RULA, WAS, HARM, NIOSH, JSI, KIM, EAWS, RAMP)
    • OFI(Opportunities of Improvements) Points Sharing
    • Support in Workplace Design Modification
    • Final Audit

    OBJECTIVE : 

    zero effect

    Zero Effect: To make the production process, product, environment friendly and good enough for social well being and sustainability of the environment.

    EXAMPLES

    • Environment Policy
    • Effect Impact Analysis & Life Cycle Assessment
    • Energy Cost Optimisation
    • Waste Management & Control

    OBJECTIVE : 

    zero defects

    Zero Defect: Developing a product that has no defects but ensuring the quality standards and reducing the defects to a level of zero in your projects.

    EXAMPLES

    • Quality Management System Awareness
    • Quality Performance (Quality KPI Development &  Tracking )
    • Non-Conformities Identification & CAPA Implementation
    • Workplace Audit
    • 7 QC Tools & 7 Management Tools
    • Problem Solving & Poka Yoke
    • Root Cause Analysis

    OBJECTIVE : 

    zero delivery failure

    Zero Delivery / Failure: To accomplish the task within the lead time without failure in inventory time, WIP storage, logistics cost, and mapping of the steps a company takes to complete a certain process.

    EXAMPLES

    • Value Stream Mapping
    • Value Supply Chain Management
    • Inventory Analysis & Management
    • Process Mapping (BPM/BPR)

    OBJECTIVE : 

    • 100% Sustenance

     

    EXAMPLES

    • Employee Training & Re-Training
    • DOJO Set-up
    • Training Content