ELIMINATE 3M

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

3M
3M is a Japanese concept derived for shop

floor improvement
It contains 3 elimination activities
Since it starts with letter M it is called as
3M

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ELIMINATE 3M

Waste in Value System

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

MUDA(WASTE)
MUDA stands for eliminating Non Value Added

activities

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

7 TYPES of MUDA
MUDA

of Production (Over Production)

MUDA of Waiting
MUDA of Conveyance (Transport)
MUDA of Over or Incorrect Processing
MUDA of Stock (Over Stock)
MUDA of Workmen Movement
MUDA of Defects

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ELIMINATE 3M

MUDA of PRODUCTION
Production more than requirement
Production earlier than requirement

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ELIMINATE 3M

MUDA of WAITING
Machine breakdown
Die breakage or die problem
Pallet shortage
Die set up time (SMED)

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ELIMINATE 3M

MUDA of CONVEYANCE
Panel changing from WIP pallets to

Despatch Pallets
Operation pending production
Unnecessary movement of fork lifts
Changing
panels from
WIP pallet to
CC pallet

ACHIEVE WORLD CLASS MANUFACTURING

Operation
pending
production

ELIMINATE 3M

MUDA of CONVEYANCE

ot size 4000 Nos

Qty/trip 500 Nos
No of trips 8

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Lot size 4000 No

Qty/trip 2000 No
No of trips 2

ELIMINATE 3M

MUDA of Over or Incorrect

Processing
Panels undergoes additional process to
satisfy the customer requirement

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ELIMINATE 3M

MUDA of STOCK

Oil spraying to avoid panel rust

Rust cleaning due to panel oil stain
Pallet shortage for less stock items

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MUDA of WORKMEN
MOVEMENT
Non value added operator movement

ELIMINATE 3M

No panel
diverter

Panel
diverter
available

Difficult to
pick the
panel

Easy to pick
the panel

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

MUDA of Defects
Production of defective parts

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ELIMINATE 3M

MURI (Over Burden)

MURI stands for any activity that exceeds actual
capacity of Equipment or Operators

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

Muri
Overburdening people results in Safety and

Quality problems
Overburdening Equipment causes Break

Downs and Defects.

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

Use of 2.5 T fork lift instead of 5 T fork lift

Lifting two dies at time with EOT crane
Press over load due to double panel

loading in the die

Double sheet feeding in shearing machine
2.762 Ton
with 2.5T
forklift

2.762 Ton
with 5T
forklift

WRONG

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CORRECT

ELIMINATE 3M

Two dies
lifted at time

One die
lifted at time

Strain while
moving the
pallet

No Strain
while
moving the
pallet

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ELIMINATE 3M

MURA (Unevenness)
MURA stands for any activity that contains
inconsistency or ineffective utilization

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ELIMINATE 3M

MURA (Unevenness)
Unevenness results from an irregular

production schedule or fluctuating production

volumes due to internal problems, like
downtime or missing parts or defects.
Muda will be a result of Mura

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

MURA
(Unevenness)

Unequal allocation of work to operators

The work load for the last operator is not
balanced with other
two operators

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

Heijunka (Level out the

Workload)
Achieving heijunka is fundamental to
eliminating Mura, which is fundamental to
eliminating Muri and Muda.

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

Heijunka (Level out the

Workload)
Heijunka is the leveling of production by both
volume and product mix

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ELIMINATE 3M

Heijunka (Level out the

Workload)
It does not build products according to the
actual flow of customer orders, which can swing
up and down wildly.
It takes the total volume of orders in a period
and levels them out so the same amount and
mix are being made each day.

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ELIMINATE 3M

Traditional
(Unleveled)

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Mixed Model
Production
(Leveled)

ELIMINATE 3M

4 Benefits of Leveling the

Schedule
Flexibility to make what the customer wants
when they want it
Reduced risk of unsold goods
Balanced use of labor and machines
Smoothed demand on upstream processes
and the plants suppliers

ACHIEVE WORLD CLASS MANUFACTURING

ELIMINATE 3M

To sustain Cost Reduction, eliminate these

3M in shop floor.

ACHIEVE WORLD CLASS MANUFACTURING