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Unit 9 - Waste Management
Unit 9 - Waste Management
WASTE MANAGEMENT
LEAN MANUFACTURING
Lean Manufacturing is a systematic methodology that
identifies and eliminates all types of waste or non-value-
added activities; not only in production or manufacturing
operations, but in the service industry as well.
Lean concepts are purely about creating more value for
customers by eliminating activities that are considered
waste. Any activity or process that consumes resources,
adds cost or time without creating value becomes the
target for elimination.
LEAN MANUFACTURING CONCEPTS
• 5S
• Kaizen
• Value Stream Mapping
• Quick Changeover/SMED
• JIT/Kanban
• Poka Yoke & Mistake Proofing
• Total Productive Maintenance
5 S HOUSKEEPING
T – Transportation
E – Excess production
A – Added processes
M – Motion
W – Waiting
I – Inventory
N – Non-conformance
Overall Equipment Effectiveness (OEE)
Overall Equipment Effectiveness (OEE) measures total
performance by relating the availability of a process to its
productivity and output quality.
OEE was first used by Seiichi Nakajima, the founder of
total productive maintenance (TPM), in describing a
fundamental measure for tracking production performance.
He challenged the complacent view of effectiveness by
focusing not simply on keeping equipment running
smoothly, but on creating a sense of joint responsibility
between operators and maintenance workers to extend and
optimize overall equipment performance.
OEE addresses all losses caused by the
equipment, including
Not being available when needed because of
breakdowns or set-up and adjustment losses
Not running at the optimum rate because of
reduced speed or idling and minor stoppage
losses
Not producing first-pass A1 quality output
because of defects and rework or start-up
losses.
Overall Equipment Effectiveness
OEE is the way to measure how effectively machine / equipment hours are used (Value
Adding)
- scrap
Effective time Quality Losses - reject
- rework
Calculation of LOSSES
Total time
e.g. 480 min. (1 shift)
- scrap
Effective time Quality Losses - rework
- rejects
250 min.
Productive Performance=
Running time - Performance loss X
Running time
Quality =
Productive time - Quality loss time X
Productive time
Collect data for all downtime Data analysis and Make improvements
and losses on the machine visible measure visible and implement
35
Analysis
Repairs 30
25
Autonomous Mainten.
20
Change over, Adjustm. 15
10 Preventive Maintenance
5
Minor stoppages 33 26 16 7 3
Standardize tooling
Scrap, rework OEE Trend
Improved machine
Target 2003
reliability
Standardisation
J F M A M J J A S O N D
Kaizen