1. Waste in Manufacturing Process Due to :
• Improper Material Handling .
2. Waste in Purchasing Due to :
1. Reducing number of basic motions:
Eliminate un-necessary motion
Reduce eye movement
Combine Two or more motions
Place materials & tools in a fixed
position in front of the Operator
Arrange material & tools in the order they
are used
Use Bins that allow material to be grabbed
easily
Move in the same direction the equipment
moves.
Combine two or more tools into one
Use mechanism that required min. tightening
force or movement
2. Reduce The Distance Of Motion :
Minimise the distance of motion
Perform motion in the optimum body position
Make the work area smallest size that is not
restrictive
For material movement use gravity driven tools
3. Moving at the same time:
Both hand should start & stop moving at
the same time
Move both hands at the same time in a
symmetrical motion but in opposite direction.
Improve Efficiency by using feet when working
with both hands.
Position the material in such a way so that
both hands can move at the same time.
Use holding tool to hold something for long
time.
Devise tools that allow both hands to move at
the same time.
4.
Making Motion Comfortable:
Make work position at comfortable
Height.
Use Gravity or inertia to produce Motion.
Alter or eliminate job requiring force
Plan direction of motion to be natural &
smoothly changed.
Use guides to restrict path of motion
Design grips to be grabbed easily.
Design tools so that position can be aligned
from a comfortable viewing position.
5.Basic
Rules for Material Handling:
Layout & Sequence to reduce distance.
Combining tasks to reduce number of trips
Making load neither too heave nor light
Using return trips for transport as well
Increase moving speed.
Eliminate manual transportation.
Decide to move goods or men.
Avoid direct operatives to transport goods.
Make transport more conveniently.
Eliminate un-necessary transportation.
q
IMPROVEMENTS IN WORK METHODS
•
Is
there a different way of doing it?
• Can you oversee more number of
machines?
• Can existing waiting time be spend
for other purpose?
• Can a singe motion replace several
motions?
• Can it be installed or removed
with one motion?
• Can a troublesome set-up be
eliminated?
• Can a Machine do a manual Task?
• Can a process be shortened or
eliminated?
• Can a rhythmical motion be used?
•
Can A more comfortable posture be used?
• Are both Hand Being Used?
• Can Your Foot be Used?
• How about changing the position of
handles , switches & levers.
q
WASTE IN HUMAN RESOURCE
Ø Individual’s
ability not used fully.
1.Elimination:
• By using labor saving devices.
• People should given tasks that
require judgement
& creativity
• All kind of manual tasks should be
mechanised.
2.
Waste in Operation:
•
Standard procedure not followed or carried out
•
Standard procedure Inefficient
•
By adding the value through increased efficiency as well as increased
production capability.
•The layouts of machines should be
on the basis of process sequence & not on the basis of kind of
process.
q
WASTE IN OFFICE WORK
1.General
& Communication :
•Information is traveling at faster
speeds. It is voluminous.
•There is not enough time to think
& plan.
•We are forced to make quick
decision.
•We
are overloaded with information & overwhelming with work
• We have so much to do with so
little time at hand . Demands, pressure, strain & tensions keep growing.
Our goal & dreams remains unfulfilled.
•Somewhere something is wrong what
to do?
•We have to pursue pleasing habits ,
not pleasing results.
2. Let the Desk Work for Us :
• Desk exists for getting work done.
• There are two specific needs I) Working area. II) Storage area
• A clean desk is a great motivation
• Avoid or eliminate cluttering of papers.
• Do not set aside papers for
decision.
• Do not begin with easy stuff ,
leaving important thing for latter.
• Do not work under pressure,
Quality will suffer.
• Organise
Activities
ü Go
through every paper.
ü
Separate important ones.
ü Go
through important papers & make master list.
ü Only
self concerning papers to be recorded in master list.
ü
Paper concerning to others should be sent
ü Get
rid of unimportant papers.
2. Master List :
• Write list on ruled pad
• Do not number item.
• Do not rewrite list daily.
• Cross out item after completion.
• Transfer the unfinished items to
next page, Only after completion of 50 % of the Items.
• Put date on the list.
• Keep master list on top of the
your desk.
•
3. Use File Folder :
• Separate folder for each customer,
vendor, project etc.
• Never put unfinished work in a
folder without noting in the master list.
• Multi cavity folder to put papers
for seven days, one moth, one year.
4. Day to Day Work :
• Putting Higher value on time will
help to save time.
• Time is money. If we waste time we
waste money.
• Find out how much waiting time
cost.
• Master your work with master list.
•Interruption , phone calls,
meetings, emergencies all steal valuable time.
•Consult master list for refreshing
memory for next day work.
•Prepare daily agenda to plan work
day.
•Give Weightage to each item on master list as per importance
•Schedule major project &
complete them before they become urgent.
•A well thought out solution is
better than impulsive one. Urgent things gives little time to think.
•Most productive time of the day is
the early morning hours.
•Respect others time, Others will
respect yours.
5. Mind Food For Us:
• For meeting decide necessity of
your presence.
•Keep the agenda short.
•Prepare your self well in advance.
• Begin & end meeting on time.
• Do not wait for latecomers.
• Take note for serving a good
reminder.
• Plan to be present a minutes
early.
• Set watch five minutes fast.
• Reconfirm time & place before
leaving for meetinhg
6. Quality Time:
• Time saved at work is time for
yourself.
• Your Daily objective should be to
get as much important work done as possible.
• Stay on track by minimising
interruption.
qFACTORY
MANAGEMENT & PROBLEM - FREE
ENGINEERING.
vPEOPLE
:
Ø Look
– Free
Ø Walk
– Free
Ø
Search – Free
Ø
Stack – free
Ø
Wasted Motion – free
vMETHODS
:
Ø
Bottleneck – free
ØInventory
– free
ØHunger
– free
ØChangeover
– free
vQUALITY
:
Ø
Defect – Free
Ø
Nonstandard – Free
vMACHINE
/ FIXTURE :
Ø Air
– free
ØConveyor
– free
ØAir
cut – free
ØOil
pan – free
Ø
Short stop – free
Ø
Corner – free
Ø Dust
– free
Ø Tool
box – free
Ø
Energy - free
vMATERIAL
PARTS :
Ø Bolt
– Free
Ø Burr
– Free
Ø
Weigh – free
Ø Spot
weld – free
Ø
Welding – free
Ø
Parts - Free
vSAFETY
:
ØRoller
accident – free
Ø
Pinch – free
Ø Body
cut – free
Ø
Crash – free
ØMistake
- free
vOFFICE
MANAGEMENT :
Ø
Paper – Free
Ø
Delivery cost– Free
Ø
Stamp – free
Ø Make
work – free
Ø Wasted motion – free
Ø walk
- Free
ØCall
– free
Ø
Bottleneck – free
Ø
Meeting – free
Ø Over
service – free
ØCopy
– free
ØIrregularity
– free
ØSmoke
- free
Ø Cash
- Free
