Production waste is an unwanted business cost - and one that could increase due to rising disposal costs, regulation and changes in customer demand.
You can help to reduce the cost implications of production waste, as well as their environmental effects - by reading our new white paper.
The guide explores the stages of production waste - and the benefits of lean production. It can be downloaded free below.
There are seven stages of production waste
When lean production originated in the Toyota Production System in Japan, they identified three general forms of waste - unproductive waste, inconsistent waste and unreasonable waste.
From here, seven stages at which production waste can be saved were identified.
By not understanding your customer's needs and producing more products than needed you're not only creating increased costs from needing more storage space, but you're also wasting resources that could be used for other products.
2. Unnecessary transport
Needing to transport goods between factories or workshops is referred to as unnecessary transport because of the wasted fuel, energy and labour, as well as wear and tear. This is a result of multiple facilities, poor layouts and bad design.
Having too much inventory is also considered waste because of the cost of storing these items. This includes raw materials, goods that are in the process of being created and completed products. Seasonal changes, overproduction or excessive purchasing can cause inventory waste.
Similarly to unnecessary transport, motion can also be considered a waste; if your employees or equipment spends time moving from location to location then this could be optimised to improve efficiency.
If you're producing defects then you're wasting time, money, resources, and customer satisfaction. Causes for defect are poor design, poor machine repair, and lack of quality control.
When you produce more products than required, this is called over-processing. This generally happens as a result of a poorly-designed process resulting from bad communication or human error.
Any waiting that your team has to do, such as unplanned downtime, broken equipment, poor planning or poor communication can result in wasted time.
Choosing a counting scale
While counting scales cannot affect every stage of waste, it can help to improve certain stages, such as overproduction, inventory and waiting. Weighing scales - and in particularly counting scales - can be used to identify and therefore reduce business waste. In turn, making businesses more efficient.
When selecting a counting scale for your production processes, Marsden has a range of counting scales which can be tailored to what you are weighing. To give you more help we’ve put together this Buyers’ Guide, and this blog post with more helpful tips.
For highly precise parts counting, the Jadever JCE has graduations to 0.1g and has an internal counting resolution to 1/600,000.
Alternatively our JIK indicator can be used for weighing or counting. It has data transfer capabilities, so weight and count readings can be recorded on a spreadsheet throughout the production process. This further helps with inventory control, production control and compliance.
For more information about any of our counting scales, contact us here or call 01709 364296.