ZERO WASTE IN MANUFACTURING
Zero Waste should be a guiding principle for all manufacturers. It is the act of striving for zero waste service itself that is leading the manufacturing industry to be greener and more cost-efficient. By embracing zero waste as a concept, industry leaders are improving their resource management and making progress towards reducing waste in manufacturing.
Controlling the materials being used in the manufacturing process and keeping the right amount of inventory (including raw materials, WIP, and FG) can reduce manufacturing waste isn’t just about “being green” – it’s a money-saving technique. The more waste you produce, the more waste you need to ship out and/or process. And that means the more frequently you have to pay for waste management. Production through the Zero Waste concept is essential not only to environmental sustainability but also for both personal and economic reasons.
What are the Benefits of Zero Waste Manufacturing?
1) Reduces waste disposal fees
2) Saves money on production costs
3) Contributes to the sustainability of your industry
4) Creates a more efficient production process
5) Generates a positive public relations image for the company
CLASSIFICATION OF WASTE
|Over Processing||Over Production|
TYPE OF WASTE
It is very important to understand the genesis of waste
The Lean focus is to remove all types of wastes
MANUFACTURING EXCELLENCE IMPLEMENTATION PROCESS
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.
- Time & Motion Study
- Lean Layouting
- ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)
- Material Handling Optimization
- OEE/ OLE
Employee Engagement: To improve workplace conditions that drive engagement and enhance employee sense of well-being.
- Basic 5S Awareness
- 1S, 2S Implementation
- Workplace Visual Management (Visual Factory)
- Kaizen Strategy Implementation
- Suggestion Scheme
- Innovative Leaders
Zero Breakdown: Maintenance is all about working for the ultimate goal with a winning maintenance strategy.
- My Machine Campaign
- Machine Utilization Monitoring
- Machine Losses Reduction
- Breakdown Analysis
- Preventive Maintenance
- 3S ,4S & 5S for Machine & Office area
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.
- OH & S Management System Implementation
- Safety KPIs
- Workplace & Safety
- Safety Signage Standardization
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.
- 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
Zero Effect: To make the production process, product, environment friendly and good enough for social well-being and sustainability of the environment.
- Environment Policy
- Effect Impact Analysis & Life Cycle Assessment
- Energy Cost Optimisation
- Waste Management & Control
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.
- 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
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
- Advance Lean Practices Implementation
- Manpower Rationalization
- Design & Process FMEA
- Line Balancing
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.
- Value Stream Mapping
- Value Supply Chain Management
- Inventory Analysis & Management
- Process Mapping (BPM/BPR)