2 - ELIMINATION OF WASTE IN THE SHOP FLOOR.pptx

Elimination of waste is one of the most important principles in improving efficiency, productivity, and sustainability in any organization or process. Waste refers to any activity, resource, or effort that does not add value to the final product or service. Identifying and removing such non-value-adding activities helps organizations save costs, optimize time, enhance quality, and improve customer satisfaction. In industries such as manufacturing, waste can appear in different forms — unnecessary movement of materials, waiting time, overproduction, defects, excess inventory, and underutilization of talent. These are often described in Lean Manufacturing as the “Seven Wastes” (Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, and Defects). By systematically identifying these wastes, teams can take corrective actions that streamline processes and create more value with fewer resources.

Eliminating waste is not limited to physical goods. In service sectors, waste may include redundant approval layers, inefficient communication, or delays in decision-making. In offices, it could mean excessive paperwork, unused reports, or meetings without clear outcomes. Whether in production or services, waste reduction directly contributes to better resource utilization and improved operational flow.

1. ELIMINATION OF WASTE IN THE SHOP FLOOR www.legionenergy.in

2. Sub-station OUR PROCESSES MUST •Minimise Waste •Minimise Lead Time •Minimise Variation •Maximise Flexibility •Maximise Quality •Maximise Workers Contribution •Continually Improve

3. Sub-station - The Waste of Inventory Defined: More product on hand than required to meet customer requirements Examples: More raw material than needed. More work-in-process (WIP) than needed. The use of a filing system for “items in process” Excess components or paperwork in the work area. Large storage areas required warehouse. The control & managements of stock Less floor space. Cash tied up in stock. Obsolete stock Inventory waste - sorting out what is not sold costs money and ties up company resources without adding any value to the product. Declining quality - storing unsold inventory increases the chance that it will have to be scrapped or reworked, which adds cost over order to meet poor processes Cost's Are Within The Control Of Your Company.

4. Sub-station - The Waste of Transportation Defined: Unnecessary movement of the item Example: Having three storage locations for the same material Poorly lay out resulting in excessive distance from stores to point of use Moving raw materials to an offsite warehouse Transporting a drawing from one location to another Locating test reports or data away from point of use Products and parts which are left standing around such as WIP or finished goods is a major cause of waste, The usual cause of excessive transportation is poor plant layout. Fork lift trucks one way trips. The layout of the equipment may not have been considered or optimised. Push production Cost's Are Within The Control Of Your Company.

5. Sub-station - The Waste of Waiting Defined: Unnecessary wait time between value added tasks Examples: Waiting for materials at point of use Waiting for a predecessor operation Waiting for a report, Email, fax, phone, orders customer Lack of communication Waiting for a decision, approval Waiting for a resource, late to a meeting Waiting for a “bottleneck” resource Waiting for machine repair Not having an agenda for a meeting Work imbalance Order entry delays Waiting for any kind of data translation Products and parts which are left standing around such as WIP or finished goods is a major cause of waste. WIP is usually cause by producing large batches rather than what is actually needed.   Cost's Are Within The Control Of Your Company.

6. Sub-station - The Waste of Overproduction Defined: Producing more of an item than the customer orders Examples : Running a machine for 16 hours when only 10 are required Making 2 days worth of product in 1 day required Performing more tests than the specification calls for Issuing more reports than are requested Reports too detailed or lengthy to meet the need “Too much” project planning Daily status report when monthly is adequate

7. Sub-station - The Waste of Motion…WASTE ENEMY No 1 Defined: Any extra motions required by the resource to perform the process task Examples: Unnecessary operator movement within the production cell / line Walking to the copy machine Searching for documents Leaving the workplace to get data to complete the task Searching for parts, tools, prints, etc. Lifting boxes of parts Good practices often reduces motion. Putting materials in set locations, keeping a area tidy will remove the need to move parts and materials around to simply make space for More. The best solution is to lay the plant out to reduce motion and the distance travelled. Cost's Are Within The Control Of Your Company.

8. Sub-station - The Waste of Over processing Defined: Any activity performed upon the item that is not required by the process or customer Examples: None value added operations building a product for four hours when only two are required Testing a product three times when the specification calls for one test Over-tight tolerances Reformatting data for multiple report formats Studies that are not needed, more detail than is necessary or required to solve a problem Including extra data in a report Measuring extra dimensions on a drawing Rework is one of the biggest causes of over processing. Poor setup of machine operations and their effectiveness will extend cycle times and reduce output Cost's Are Within The Control Of Your Company.

9. Sub-station - The Waste of Scrap / Rework Correction Defined: Any task that is not performed right the first time or done more than once. Examples: Scrap & rework Field failure Missing parts Re-torque a bolt Sorting incoming materials Checking a key dimension Trimming thread or flash from a component Rewrites / reformats of data Design or project reviews Entering data into a computer more than once Incapable machines Miss-loaded part Any inspection steps Any design or specification changes Cost's Are Within The Control Of Your Company.

10. Sub-station Defined: Not acting upon the good ideas of employees, not incorporating labor saving devices or systems when feasible Examples: Lack of a formal suggestion system Lack of a timely response to requests Separate, incompatible systems for process tasks Re-assignment of resources before tasks are completed Poor Discipline Inadequate Training Not listening to ideas No involvement from workforce; not capturing improvement ideas Not taking action on them Poor morale. - The Waste of People & Creativity / behavior Cost's Are Within The Control Of Your Company.

11. Sub-station Reduce your cost by Helping you to understand how to improve your processes. Improve your capacity. Reduce work in progress. Improve your value added ratio. Improve quality cost deliver & people contribution. Understand the variation in your processes. Become pro-active rather than re-active. 5`s A place for ever thing & every thing in it's place. Improve your supplier & Impress your customer. Win new orders. Meet cost down targets & still make a profit. Make cost reduction through waste elimination. Increased labour flexibility & productivity. Introduce flexible manpower systems. Operators & shop floor loaded to takt. One piece product flow. Multi skilled work force. Improve your RFT. Reduce lead time & inventory. Reduce inventory turn stock back into cash. Production Catch back ability. Set up kpi`s performance monitor Display & understand variation. Improve your quality performance to customer.

12. Office: No.203, Brigade Rubix, HMT Main Road, off Tumkur Road, Opp. BFW Factory, Bengaluru - 560 013 Factory : Plot No. 61,62 & 63, Obadenahalli Ind. Area, KIADB Phase -III, Doddaballapura Tq ., Bengaluru - 561 203 [phone] / 4042 [phone] / 5101 [email protected] www.legionenergy.in