Waste Management

For assistance call: Amandeep Singh Gujral

+91-78375-43000 Industrial Engineer

What is Waste?

• Any resource or activity which adds no value to the output is waste.

• Anything which leads to error, defect and injury is considered waste.

3 Major Categories of Waste

• Mura-Unevenness

• Muri-Overburdening

• Muda-7 types of waste.

Types of Waste

• There are 7 types of waste:

Transport Inventory Motion Waiting

Over processing

Over production

Rework

TIMWOOR Matrix

TIMWOOR Matrix

Process Name: Process Location:

Types of Waste: Describe Waste Cause of Waste Solution Control

Transport

Inventory

Motion

Waiting

Over-Production

Over-Processing

Rework

TIMWOOD table is used to identify the types of waste hidden in each process. Starts with defining the waste then identifying the cause and their possible solutions and finally control plan.

Description of Waste

Identification Of Waste

Typify waste

Step Wise approach to identify Waste

Process Walk Through

Process Walk Through Process Name Process Location

Steps Description VA/NVA Type

1

2

3

4

5

6

7

8

9

10

All non-value added steps are waste. Next step is to typify the waste according to TIMWOOR.

TIMWOOR Matrix

TIMWOOR Matrix

Process Name: Process Location:

Types of Waste: Describe Waste Cause of Waste Solution Control

Transport

Inventory

Motion

Waiting

Over-Production

Over-Processing

Rework

TIMWOOD table is used to identify the types of waste hidden in each process. Starts with defining the waste then identifying the cause and their possible solutions and finally control plan.

Causes Identification

Possible cause (Fish-bone Diagram)

Prioritization of cause

Fish-Bone Diagram (Possible causes)

Waste

Materials

Method Person Equipment

Measurement Environment

Cause

Cause

Cause

Cause

Cause

Cause

Cause

Cause

Cause

Cause

Cause

Cause

Cause

Cause Fish-Bone Diagram Should be constructed for all types of non-value added steps listed out in define phase.

Cause Prioritization Cause Prioritization Matrix

Impact

% Contribution

to waste

-ev effect

on Quality

%

Contributio

n to Cost

Final

Score Weightage 10 10 10

C

a

u

s

e

s

Cause-1 0

Cause-2 0

Cause-3 0

Cause-4 0

Cause-5 0

Cause-6 0

Cause-7 0

Cause-8 0

Cause-9 0

Cause-10 0

Cause Prioritization Matrix should be constructed for every Fish-Bone Diagram constructed. This is done through Brain Storming.

Solution Selection

Possible Solutions Solution Selection

Generate Solutions

Solution Generation

S.No. Valid Causes Possible solutions

1

1.1

1.2

1.3

1.4

2

2.1

2.2

2.3

2.4

3

3.1

3.2

3.3

3.4

Selection Process

Solution Selection

S.no. Solution

Easy to

implement

Fast to

implement

Cheap to

implement

Within team’s

control

Easy

reversible

No Side

Effects

1.1

1.2

1.3

1.4

1.5

Answer in yes/no. every yes=1 and every No=0. Acceptability Criteria Depends upon your choice

Solution with 100% score should be implemented without further analysis .

Evaluate generated possible solution for each cause separately

Process evaluation after Improvement

• Calculate the % reduction of non-value adding steps

• Quantify % waste reduction.

• Calculate cost saving done.

• Calculate % increase in productivity.

Control

Control measures are implemented to prevent the occurrence of same errors which are eliminated during improvement over time

Types of Control

• Engineering Control-

• Administrative Control

• Work Practice controls

Engineering control

2. Error Detection and Alarms

1. Guide Pins 3. Limit Switches

4. Counters

Work Practice Control

• Work practice controls are procedures that reduce the likelihood of waste generation by altering the way in which a task is performed.

– E.g. Design the SOP with maximum % of value added steps.

Administrative control

• Giving proper training to the employees.

• Job rotation- helps destroy monotony

• 5S sustenance plan

• Visual control and checklist

• Color Coding

Thank You

References: • Toyota way • http://leanman.hubpages.com/hub/Seven-Wastes • http://yalindanisman.wordpress.com/2012/06/08/

mura-muri-ve-muda/