Waste manifests in many forms and costs industry millions of dollars each year. To stay competitive it’s essential to identify and then systematically eliminate all forms of waste that exist in the manufacturing process. This blog focuses on helping identify and offering solutions for the various forms of waste that exist for manufacturers that utilize industrial fluids in their manufacturing process.
In the context of this blog, we refer to waste per Deming’s definition, anything that doesn’t add value to the manufacturing process, anything that doesn’t help create conformance to the customers’ specification and/or anything your customer would be unwilling to pay you to do. Waste is therefore not limited to the actual waste streams produced by the facility, it’s any poorly managed resource or activity that leads to excessive resource usage or consumption. Lean Principles follow a systematic identification and then elimination of all sources of waste and wasteful activities. Below are some of the waste examples we will be exploring in this blog.
Using Lean’s 8 Forms of waste, Zimmark’s Z-ROW program looks to employ a continuous improvement philosophy whose goal is the ongoing and systematic elimination of all these sources of waste in a manufacturing environment:
• Talent – using the wrong people for the wrong purpose is a massive and costly form of waste for any manufacturing facility. By establishing systems and strong business process to take day to day variability away from the manufacturing process, your talent can stay focused on where their specialized knowledge can have the biggest impact
• Inventory – this category of waste manifests in many different forms, from having too many different kinds of products when less will do, to having too much of any one product on site at any given time. In the context of industrial fluids, we see so many companies have “too much” product in their sumps as they let their concentrations get excessively high. This hidden form of waste drives costs up needlessly and left unchecked threatens the process in many other ways
• Motion – unnecessary steps – needless activity. By engineering the process with inherent stability in mind and actively looking for ways to reduce motion, frees up so much time/effort to stay focused on more important tasks and activities
• Waiting – the gap in time between process steps can extremely wasteful. Engineering out the bottle necks that create wasted time and effort needs to be a priority in any business looking to maximise profits and minimise waste. In a process control context, the time that exists between sample collection and corrective action creates significant waste and potentially puts the process at risk
• Transportation – the unnecessary movement of products, materials or personnel saps productivity and creates needless activity. For example time based PM’s performed on systems is a massive form of waste that generates several forms of waste and unnecessary cost.
• Defects – Defects result from un-managed process variability. Quality goes up when variability goes down. Understanding the cause and effect of the various factors that impact quality is the key to reducing this significant waste stream.
• Overproduction – Understanding that more is not always better is the key to addressing this source of waste. Producing more than is required drives up waste and expends precious time/resources that need to be focused on more productive areas.
• Overprocessing – results when more work or higher quality than the customer requires is put into a process. Knowing the right amount of work/effort without creating defects as defined by the process or the customer is essential.
Fluid usage and fluid waste impacts many areas of the manufacturing process:
Fluid Use Waste Impacts
-Health and Safety Risk
-Environmental Compliance (legal)
-Environmental Sustainability by minimizing Impact
-Overall Equipment Effectiveness (OEE)
o Process Availability (uptime)
o Process Yield (quality)
o Process Throughput (speed)
o Price (Unit cost)
o Volume (product consumed, waste generated)
o Process Control
o Problem solving
o Continuous Improvement
Z-ROW looks at each of these aspects of fluid usage and disposal in a manufacturing context, and systematically eliminates all the forms of waste, to ensure the core manufacturing process is supported and the impact on fluids is minimized.