SEMINAR PRESENTATION

ON
WASTE ELIMINATION TOOLS IN
INDUSTRIES
Presented to, Presented by,
Dr. V.N. Shukla (Professor) Sudhir Kumar
Mr. Sanjay Singh ( Asst. Professor) 15EGJME168

DEPARTMENT OF MECHANICAL ENGINEERING

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GLOBAL INSTITUTE OF TECHNOLOGY, JAIPUR 2/9/2019
 CONTENTS
 What is Value?
 What is waste?
 The 8 types of waste.
 Waste elimination tools.
 What is 5S?
 Targets of 5S.
 5S steps of good maintenance
 Seiri
 Seiton
 Seiso
 Seiketsu
 Shitsuke
 Advantages
 5S in Indian industries.

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 WHAT IS VALUE?
 A measurement of worth of a product, or service, by a
customer based on its usefulness in satisfying a customer
need.
 An activity, process or operation that changes the product
from one form to another in order to get it closer to the
customer specifications.
 It is something that the customer is willing to pay for.

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 WHAT IS WASTE?
 Any activity that adds costs or time but does not add value.
 Consuming more resources (time, money, space etc) than are
necessary to produce the goods, or services, that the customer
wants.
 Pure waste – Actions that could be stopped without affecting the
customer.
 Incidental waste – Actions that need to be done based on how the
current system operates but do not add value.

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 THE 8 TYPES OF WASTE
 Overproduction
 Inventory
 Transportation
 Motion (Operations)
 Processing
 Defects
 Waiting
 People’s Skills

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 OVERPRODUCTION
 Supplying the process with more than is needed to meet order
requirements, sooner or faster than it is needed, causes
almost all other types of waste.
 This is the worst waste of all, because it helps cause all the
other.

Common Causes –
Producing more than is required to make
up for yield loss.
Scheduling production to forecasted
demand.
Long changeovers or avoiding changeovers
lead to large lot production.

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 INVENTORY
 Require people, processes and time to count, process,
execute, store and maintain it.
 If we do not get orders the items processes will not be useful
and would be waste of time and effort.
 Inventory is often used to help hide other wastes.

Common Causes –
Overproduction/Overprocessing.
Long changeover times between
processes.
Defective or questionable items.
Mismatched production speeds.

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 TRANSPORTATION
 Double or triple handling, of documents.
 It adds no value and is often used to get the extra inventory
out of the way.

Common causes –
Extra inventory
Retention points before and after
operations
Excessive distance between
operations (layout)
Single skill focused operations.

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 MOTION (OPERATORS)
 Walking without working (away from workstation)
 Searching for documents, tools, materials or information.
 Reaching, bending or unnecessary motion due to poor
housekeeping or workspace layout.
 Process is not designed with employees in mind.

Common causes –
Poor workstation layout
Isolated operations
Shared tools
Fatigue
Workstation congestion

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 PROCESSING
 Doing more than is necessary to produce an effectively
output.
 Extra setup steps, over-specification of the process, extra
processing steps

Common causes –
Lack of standard work or processes
Equipment over designed
Processes not updated with technology
changes
Lack of effective problem solving

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 DEFECTS/QUALITY
 Defective and defects.
 Cost of inspecting defects.
 Responding to customer complaints.
 Rework or re-inspection or questionable matter.

Common causes –
Emphasis on downstream
inspection; questionable matter
passed on
Lack of standard work
Info/docs handling (transportation)
Process design/Procedures

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 WAITING
 Associates waiting for the work to come in.
 Process waiting for completion of a certain activity.
 Waiting for docs, instructions, approval, information,
maintenance decisions.

Common causes –
Mismatched production rates.
Poor layout, co-ordination
Lack of coordination between
processes
Insufficiently staffed

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 PEOPLE’S SKILLS
 Employees are seen as a source of labour only, not seen as
true process experts.
 People are told what to do, and asked not to think.
 Employees are involved in finding solutions, opportunities to
improve our process are missed.

Common causes –
Management does not involve
employees in problem solving
Narrowly defined jobs and expectations
Old school management, worker
relationships

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 WASTE ELIMINATION TOOLS
 5S Method.
 Discovery and elimination of waste.
 Poka Yoke method.
 Andon.
 Multi-machine manipulation.
 Kaizen.
 From protection of employees and protection of an individual
to a reduction of the number of employees.
 Just in time manufacturing.
 Kanban.
 Production leveling (Hei-junka)

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 WHAT IS 5S?
 5S is a philosophy and a way of organizing and managing the
workspace and work flow with the intent to improve efficiency
by eliminating waste, improving flow and reducing process
unreasonableness.
 Improvement of Working Environment.
 Productivity and safety enhancement technique.
 Housekeeping technique.

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 TARGETS OF 5S
 ZERO Conversion
 ZERO Defects.
 ZERO Waste.
 ZERO Delays.
 ZERO Injuries.
 ZERO Breakdowns.

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 FIVE S OF GOOD MAINTENACE
 In Japanese 5S is the short form of five words which present
the concept of good maintenance.
 SEIRI
 SEITON
 SEISO
 SEIKETSU
 SHITSUKE

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 SEIRI (SORT)
 Decide what you need.
 Remove unnecessary clutter.
 All tools, gauges, materials, classified and then stored.
 Remove items which are broken, unusable or only
occasionally used.

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 RED TAG TECHNIQUE
 Give staff red labels
 Ask staff to go through every item in the workplace.
 Ask if needed & those that are needed, in what quantity?
 Not needed red tag it.
 Store in the red tag area.

Red
Tag

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 SEITON (ORDERLINESS)
 Once you have eliminated all the unneeded items.
 Now turn to the left over items.
 Organise layout of tools and equipment
 Designated locations
 Use tapes and labels
 Ensure everything is available as it is needed and at the ‘Point of use’

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 SEISO (CLEAN/SHINE)
 Create a spotless workplace.
 Identify and eliminate causes of dirt and grime – remove the
need to clean.
 Sweep, dust, polish and paint.
 Divide areas into zones.
 Tools and equipments must be owned by an individual.

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 SEIKETSU (STANDARDISE)
 Generate a maintenance system for the first three S’s.
 Develop procedures, schedules, procedures.
 Regularly audit using checklists and measure of
housekeeping.
 Real challenge is to keep it clean.

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 SHITSUKE (SUSTAIN)
 Means inoculate courtesy and good habits.
 Driving force behind all 5S
 Deming’s point number 1 : Consistency of purpose
 Make it a way of life.

 Part of health and safety.

 Involve the whole workforce.

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 ADVANTAGES
 If tools and materials are conveniently located in uncluttered
work areas
 Operators spends less time looking for items.
 Leads to higher workstation efficiency.
 A clean and tidy workplace leads to –
 Greater well being.
 Increased motivation.
 Health and safety is ensured.
 Machine maintenance.
 Company image improves.
 Results in a place easier to manage.
 Everyone knows where the things are supposed to be.
 Time saving.

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  Visual management system –
 Visual control to see the abnormalities.
 Simple signals/Alarms that provide an understanding of the condition
(Normal/Abnormal)
 Accidents & mistakes minimized.
 Increases space.

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 5S IN INDIAN INDUSTRIES
 BHEL
 L&T
 Jyoti CNC
 Watermann pump
 Toyota and most of automobile companies.

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 REFERENCES
 http://www.velaction.com/waste-transportation/
 https://en.wikipedia.org/wiki/Muda_(Japanese_term)#Unused_skills
 https://www.allaboutlean.com/muda/
 http://leanmanufacturingtools.org/106/waste-of-inventory-causes-
symptoms-examples-solutions
 https://www.emsstrategies.com/dm090203article2.html

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