scrap project

Content :
• Introduction.
• Types of scrap.
• Quantity of scrap for each machine.
• Percentage of scrap for each
machine.
• Root cause of scrap.
• Improvement actions .
introduction
 Scrap defined as the material that we will not be
able to recycle it again.

 Target of scrap is 1% from the over all raw

material used.

 Our current state is about 1.8% . (2020)

 We should find the root causes of scrap and also

find an improvement actions.
Types of scrap

 Mixed colors.(‫)رايش خليط الوان‬

 Dirty bulks. (‫)كالكيع متسخه‬

 Dirty growths .((‫ديل ورقبه متسخ‬

 Dirty mixed Granules (‫ خامه متسخ‬+ ‫)رايش‬

Types of scrap
 The following table and chart showing the
amount of every type of scrap during 2020.
Mixed colors

 it is obviously appears in crushers section.

 So we need to measure this type of scrap .

 During the duration 19 Jan to 19 Feb (2021).

We measure the quantity of scrap related to
the crushers output .
Root cause of mixed color of scrap

 Using brain storming technique :-

 Changing crushers from color to another.

 Over storage.

 Using un thermal adhesive.

 Spacer between crusher parts .

 Some crushers need auto loader.

Improvement directions

 Reduce changes by increase number of

crushers.
 Apply 5s and first in first out technique .

 Using thermal adhesive for the containers.

 Periodic maintenance for the crusher and

provide spur parts.
 Provide auto loader for the crushers.
Improvement actions

 After applying some improvement directions

like :-

 5S and first in first out technique

 we measure the quantity of scrap and its

percentage VS crushers out put (19 jan-19
Feb. 2021)
Continued

Crushers output ratio vs Crushers scrap within a month

0.60%

0.50%

0.40%

0.30%

0.20%

0.10%
percentage

0.00%
n n n n n n n b b b b b b b b b
- Ja - Ja - Ja - Ja - Ja - Ja - Ja Fe -Fe -Fe -Fe -Fe -Fe -Fe -Fe -Fe
-
19 121 123 125 127 129 131 02 104 106 108 110 112 114 116 118
B1 B B B B B B B1 B B B B B B B B
Continued
 Machines scrap VS productivity

 The following data for Oct-2020

Machine number productivity(kg) scrap quantity(kg) scrap % for each machine
W5C-429 23743 0 0.00%
W5C-430 8349 0 0.00%
W5C-431 0 0 #DIV/0!
W5A-412 5940 11.75 0.20%
W5B-410 10852 22.9 0.21%
W5B-406 7102 25.3 0.36%
W5B-408 13085 26.5 0.20%
W5B-407 22014 26.75 0.12%
W5A-402 3409 27.5 0.81%
W5A-417 6888 28 0.41%
W5A-403 8545 28.6 0.33%
W5B-409 14642 29.5 0.20%
W5B-415 12718 29.6 0.23%
W5A-401 5917 36.18 0.61%
W5B-419 22751 46.5 0.20%
W5A-404 12289 50.65 0.41%
W5A-418 6709 51.7 0.77%
W5A-414 26284 66.25 0.25%
W5C-412 0 66.4 #DIV/0!
W5C-428 26686 74.6 0.28%
W5C-427 57788 92.7 0.16%
W5A-405 8173 95.65 1.17%
W5C-421 17298 112 0.65%
W5B-426 39378 118.8 0.30%
W5C-422 28361 149.3 0.53%
W5C-425 38705 161.4 0.42%
W5C-424 42833 166.7 0.39%
W5C-423 47770 255 0.53%
 Machines scrap VS productivity
 The following data for Oct-2020

scrap % for each machine

scrap quantity(kg) per
1.40% 300

scrap % for each

machines
1.20%
machine 250
scrap quan-
1.00% tity(kg)
200 Moving aver-
0.80% age (scrap
150 quantity(kg))
0.60%

0.40% 100

0.20%
50

0.00%
0
 Machines scrap VS productivity
 The following data for Nov- 2020
Machine number productivity(kg) scrap quantity (kg) scrap % for each machine
W5C-430 16243 0 0.00%
W5C-412 0 0 #DIV/0!
W5C-431 0 0 #DIV/0!
W5A-402 3041 9.5 0.31%
W5A-404 11643 12 0.10%
W5A-403 9342 12.8 0.14%
W5B-406 3824 14 0.37%
W5A-412 8507 15 0.18%
W5B-407 15579 15.5 0.10%
W5B-409 17784 16.5 0.09%
W5B-408 10520 20 0.19%
W5A-401 6803 20 0.29%
W5B-410 7436 22.5 0.30%
W5B-415 10898 23 0.21%
W5A-417 6187 26.8 0.43%
W5B-419 11134 34.5 0.31%
W5A-405 9611 37.5 0.39%
W5A-418 6518 40.4 0.62%
W5C-421 16740 66.4 0.40%
W5A-414 14280 69 0.48%
W5C-429 24004 74.6 0.31%
W5C-428 22952 92.7 0.40%
W5C-422 26837 112 0.42%
W5B-426 60649 138.5 0.23%
W5C-423 34492 149.3 0.43%
W5C-427 48627 161.4 0.33%
W5C-425 41267 166.7 0.40%
W5C-424
42003 255 0.61%
 Machines scrap VS productivity
 The following data for Nov- 2020

scrap % for each machine scrap quantity (kg) per

0.70% scrap % for 300 machines
each machine
0.60% Moving aver- 250
scrap quantity
age (scrap %
0.50% (kg)
for each ma- 200
chine)
0.40%
150
0.30%
100
0.20%
50
0.10%

0
0.00%
Machines scrap VS productivity
 The following data for Dec -2020
Machine number productivity(kg) scrap quantity (kg) scrap % for each machine
W5B-408 9992 3 0.03%
W5B-406 4839.5 6.5 0.13%
W5B-407 5288.5 7.5 0.14%
W5B-409 21695 9 0.04%
W5C-431 6366 10 0.16%
W5C-412 4027 12 0.30%
W5B-410 9840 17 0.17%
W5A-401 4258 17 0.40%
W5B-415 7577.2 17.2 0.23%
W5A-412 2366.5 19.5 0.82%
W5C-430 17105 20 0.12%
W5A-417 4443.5 20.5 0.46%
W5A-404 8714.5 26.5 0.30%
W5A-402 4065.7 30.7 0.76%
W5A-403 5880.5 35.5 0.60%
W5A-405 7533.6 39.6 0.53%
W5A-418 12202.9 42.9 0.35%
W5B-419 15111.6 57.6 0.38%
W5A-414 5488.4 64.4 1.17%
W5C-422 19484 68 0.35%
W5C-421 11918.1 72.1 0.60%
W5C-429 14280.7 79.7 0.56%
W5C-424 25827 85 0.33%
W5C-428 15419.5 98.5 0.64%
W5B-426 43937.15 117.15 0.27%
W5C-423 38478.1 140.1 0.36%
W5C-427 25897.7 154.7 0.60%
W5C-425 27950.8 154.8 0.55%
Machines scrap VS productivity
 The following data for Dec -2020

scrap % for each machine

scrap quantity (kg)
1.40% 180

1.20% 160
scrap % for each 140 scrap quantity
1.00%
machine (kg)
120
0.80% Moving aver-
100 age (scrap
0.60%
quantity (kg))
80
0.40%
60
0.20%
40
0.00%
20
5 6 9 4 5 4 2 1 9 8
- 42 -42 -42 -41 -40 -40 -41 -40 -40 -40
B B B 0
5C W5 5C 5A 5A 5A 5A 5A W5 W5
W W W W W W W
Machines scrap VS productivity
 The following data for Jan -2021
Machine number productivity(kg) scrap quantity(kg) scrap % for each machine
W5A-412 0 0 #DIV/0!
W5B-408 12624 3 0.02%
W5B-409 21215.3 6.3 0.03%
W5B-407 16369.6 6.6 0.04%
W5B-406 5818.8 8.8 0.15%
W5C-424 26869 11 0.04%
W5B-410 10405 11 0.11%
W5A-401 4490.5 13.5 0.30%
W5A-417 4764.6 13.6 0.29%
W5A-405 4273.6 19.6 0.46%
W5A-402 3238.3 22.3 0.69%
W5A-403 10275.9 24.9 0.24%
W5B-415 10694.45 32.45 0.30%
W5C-430 14634 34 0.23%
W5A-418 13264.1 36.1 0.27%
W5A-404 13281.2 36.2 0.27%
W5C-431 12292 38 0.31%
W5C-412 11520 45 0.39%
W5B-419 16495.7 55.7 0.34%
W5A-414 11667.1 64.1 0.55%
W5C-429 21675.8 108.8 0.50%
W5C-422 22686 110 0.48%
W5C-421 12206.2 111.2 0.91%
W5B-426 65551 132 0.20%
W5C-428 23949.7 164.7 0.69%
W5C-423 35180.8 297.8 0.85%
W5C-425 36584.6 312.6 0.85%
W5C-427 34965.3 315.3 0.90%
 Machines scrap VS productivity
 The following data for Jan -2021

1.00% 350 scrap quantity(kg)

0.90% scrap % for each machine 300 scrap quan-
0.80% tity(kg)
scrap % for each 250
0.70%
machine
0.60% 200
0.50%
150
0.40%
0.30% 100
0.20% 50
0.10%
0
0.00%
7 8 2 9 4 5 5 4 7 2
27 23 26 22 14 12 04 30 03 05 01 10 07 08 - 42 - 42 - 42 - 41 - 40 - 41 - 40 - 42 - 40 - 41
B B B
-4 -4 -4 -4 -4 -4 -4 -4 -4 -4 -4 B-4 B-4 B-4 5C 5C 5C W5 5A W5 5A 5C W5 5A
5C 5C 5B 5C 5A 5C 5A 5C 5A 5A 5A 5 5 5 W W W W W W W
W W W W W W W W W W W W W W
Vital machines
Vital machines
Vital machines

scrap quantity(kg)
350
scrap quantity(kg)

300 Moving average (scrap quantity(kg))

250

200

150

100

50

0
7 3 6 2 4 2 4 0 3 5 1 0 7 8
- 42 - 42 - 42 - 42 - 41 - 41 - 40 - 43 - 40 - 40 - 40 - 41 - 40 - 40
5C 5C 5B 5C 5A 5C 5A 5C 5A 5A 5A 5B 5B 5B
W W W W W W W W W W W W W W
State of vital machines
Vital machines root causes &improvement directions

 W5C-423 &W5C25 :-root causes

 Mixing raw material manually .

 Discharging the machine when there is a

problem .

 Conveyor state .

 Over filling for growths container .

Vital machines root causes &improvement directions

 W5C-423&W5C-425:-improvement directions

 Using a mixer for mixing the raw material or put the raw
material in large container .

 Bring the secondary conveyor that take the growths to the

container.

 Suction for internal body of the machine .

Vital machines root causes &improvement directions

 W5C-427 rout causes:-

 Mixing raw material manually .

 Spacers between the conveyor and machine body.

Vital machines root causes
&improvement directions
 W5C-427 improvement actions:-

 Using a mixer for mixing the raw material or put the

raw material in large container.

 Bring the secondary conveyor that take the growths

to the container.