Production waste control

By
Monday Michael
 Contents

Introduction
Types of Waste in Production Processes
Causes of Waste in Production Processes
Lean Manufacturing Principles for Waste Reduction
Benefits of Production Waste Control
Conclusion
 Introduction to Production Waste Control

Production waste control refers to the practices and

strategies implemented by manufacturers to minimize the
amount of waste generated during the production process.

This involves reducing, reusing, and recycling materials,

energy, and other resources used in production, with the
goal of reducing the impact on the environment, increasing
efficiency, and improving profitability.
Types of Waste in Production Processes

RAW MATERIALS WASTE

ENERGY WASTE
WATER WASTE
PACKAGING WASTE
BY-PRODUCT WASTE
 Causes of Waste in Production Processes

OVERPRODUCTION
DEFECTIVE PRODUCTS
UNNECESSARY PROCESSING
UNUSED RAW MATERIALS
POORLY DESIGNED PROCESSES
Lean Manufacturing Principles for Waste Reduction

JUST-IN-TIME (JIT) PRODUCTION

TOTAL QUALITY MANAGEMENT (TQM)
CONTINUOUS IMPROVEMENT (CI)
5S WORKPLACE ORGANIZATION
 Just-in-Time (JIT) production

JIT production is a manufacturing philosophy and

technique that aims to minimize waste and improve
efficiency by producing goods only when they are
needed, in the exact amount required.
JIT production is based on the principles of Lean manufacturing
and is often achieved by using data and technology to balance
the production process with demand.
The key benefits of JIT include reduced costs, improved cash
flow, increased responsiveness to customer demand, and at the
end reduced waste due to overproduction or stock obsolescence.
 Total Quality Management (TQM)
(TQM) is a management approach that seeks to optimize the quality of
an organization's products and services by involving all employees in a
continuous improvement process.
The key components of TQM include:
A strong customer focus
Involvement of all employees
A continuous improvement culture
Use of data and metrics to drive improvements
Effective leadership and teamwork
TQM can help organizations improve efficiency, reduce costs, increase
customer satisfaction, and at the end reduces production waste.
 Continuous Improvement (CI)
Continuous Improvement (CI) is based on the idea that there is
always room for improvement, and that an organization can
continually get better by continuously identifying and resolving
problems and making small changes.

CI is an effective way to control waste in production processes by

continuously identifying and reducing waste, improving
efficiency, and reducing the impact on the environment. By using
CI principles and methods, organizations can identify and
eliminate waste in all areas of their operations, from product
design to production to distribution.
 5S workplace organization
The 5S method is based on five key principles:
1. Sort (Seiri): Sort through all the materials, tools, and equipment in the workplace and keep
only what is needed.
2. Simplify (Seiton): Organize the remaining materials, tools, and equipment to make them
easy to find and use.
3. Shine (Seiso): Clean the workplace and maintain a clean environment through regular
cleaning and inspections.
4. Standardize (Seiketsu): Create and implement standard procedures and routines for
sorting, simplifying, shining, and maintaining the workplace.
5. Sustain (Shitsuke): Make the 5S principles a permanent part of the workplace culture
through continuous improvement and employee training.
By implementing the 5S method, organizations can reduce waste and improve efficiency by
reducing the amount of clutter and unused materials in the workplace, improving the flow of
work, and creating a more organized and safe work environment.
 Conclusion
Production waste control is a critical component of any organization's
efforts to increase efficiency, reduce costs, and improve environmental
sustainability. There are several effective methods for controlling
waste in production, including Just-In-Time (JIT) production, Total
Quality Management (TQM), Continuous Improvement (CI) and the 5S
workplace organization method. By implementing these methods and
continuously seeking to improve processes and reduce waste,
organizations can achieve a more efficient, cost-effective, and
environmentally responsible approach to production.