Engineering Management &

Economics

Elimination of Wastages
Eliminate Waste

What is waste?
All non-value
added activities
that customer
doesn’t pay you
to do!
 Eliminate Waste

Types of waste:
▪ Overproduction
▪ Inventory
▪ Repair/rejects
▪ Motion
▪ Processing
▪ Waiting
▪ Transport
▪ Line Layout
▪ Long Lead Times
 Ask Why?

In the factory, problem solvers should ask “why” not

once, but five times. Often the answer to the problem is
not the root cause. Asking why several times will dig
out several causes, one of which is usually the root
cause.
Why are you throwing sawdust on the floor?
❑ “Because the floor is slippery and unsafe.”
 Why is it slippery and unsafe?
❑ “Because there is oil on it.”
 Why is there oil on it?
❑ “Because the machine is dripping.”
 Why is it dripping?
❑ “Because oil is leaking from the oil coupling.”
 Why is it leaking?
❑ “Because the rubber lining inside the coupling is worn out.”
 Mistake Proofing

Errors are Inevitable!

▪ People always make mistakes (Just accept it)
▪ We will Sort it later.
▪ With this type of attitude the customer can get a
defective part.
Errors can be eliminated!
▪ Any kind of mistake people make can be reduced or
eliminated
▪ People make fewer mistakes when they are supported by
proper training and by a production system based on the
principle that errors can always be prevented
 Process Flowchart

• Always flowchart the process for proper understanding (of the

current process) and to provide focus.
• A flow chart is a picture or map that shows all of the possible
steps or elements of a process and the relationship between
these elements. Flowcharts are an excellent tool to:
– Document and understand the current process
– Analyze the current process to identify improvement
opportunities. This is done by identifying waste and trouble
spots in the current process by flowcharting the steps the
process should take if everything works right.
Particularly important for service areas
NOTE: A structured process does not exist if it cannot be
flowcharted.
 Process Flowchart
• Symbols used in process flowcharts

Start/End Block Procedural Step

Connector
Decision Block
w/Direction of
Flow
 Make a Process Flowchart
1. Select process
2. Define the process boundaries
3. Determine the level of detail
4. Write a description of the process
5. Identify each function and associate them with their
appropriate symbol
6. Draw symbols in sequence
7. Keep charts simple and consistent in level of detail
8. Use chart to identify waste and areas for
improvement in the process
 Part Weight Reduction Process

After establishing first piece,

collect 25 consecutive sample
parts at proposed part weight.
All measurements are
recorded on data collection
forms with sample # and
Measure all defined clearly marked time of
characteristics on each part. measurement .

No
Are parts in spec.? Take corrective action.

Yes

Monitor warp and sink on the 25 Yes

Is project feasible?
parts after 24 hours.

No

No
Are parts in spec.? STOP

Yes

Assemble 5 random parts with

shed, leave outside, and monitor
for 48 hours.

No
Is assembly okay?

Yes
Send 5 parts to Wooster for
evaluation. Write a deviation
and implement new part weight.

Upon approval from Wooster,

initiate CNI!
 Process Improvement
Does the activity in question add value for the customer?
IF NOT
• Can the operation be:
– Eliminated
– Simplified
– Changed in sequence
– Combined
– Standardized
without altering the value added function of the
operation?