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IndustrialManufacturing Process Improvement: Eliminating waste in motion
One form of waste targeted in Lean manufacturing is the waste of excess motion.
This isn’t to be confused with the waste of transportation (moving materials from one location to another). This is about how much motion is required to complete the task, once the parts or materials get to a workstation. What type of motion is considered waste? There are two types of motion that happen – either the motion of the parts and materials (repositioning them so they can be worked on) or the motions that a worker needs to do to perform their task (for example, turning a wrench or screwdriver). Besides wasting time, repositioning parts and materials can lead to other problems. The more you move them, the higher chance you have of dropping them, breaking them, damaging them, etc. This leads to more time wasted getting things in place again and potential re-work to repair damaged items. In addition, look at the time a worker spends performing their task. Are they constantly looking for a missing tool or part? Do they turn a part over repeatedly, to perform different steps? Do they need to change position to get a new tool or part? If they run out of an item, like screws or washers, how long does it take them to re-stock? Remember, your focus here is to decrease the time spent getting ready to do work, and try to spend most of the time actually doing the work. How can wasted motion be eliminated? One way to eliminate wasted motion is to ensure that everything can only be in the correct place and position. When the part is delivered to the workstation, whether on a cart or conveyor belt, see if you can prepare it so it can immediately be worked on. If a tool needs to be in a certain position, build the workbench so it can only be placed in the correct position. Build racks to hold each tool in the same place, in a position that makes it easy to start using. This will eliminate any time that a worker may spend trying to find where they set it down after they last used it. If there are any additional parts needed, like screws or washers, put them in the same place every time. You may also think about having one runner restocking those parts for all workstations, instead of having your operators slow down production by halting work while they get more parts. Clearly label any parts that are used for each task. If a step requires using a certain size screw, and the operator grabbed a different size (because it wasn’t clearly identified), they’ll end up wasting time getting the correct size. Ask the workers if there is anything they repeatedly spend time doing that they think can be improved. They are the real experts in what it takes to complete their task, and they often can give you a long list of changes to make their work take less time. You can talk about... Manufacturing Process Improvement: Eliminating waste in motion Tags: • tools • workbench • repositioning parts • worker • transportation • manufacturing process • process improvement • lean manufacturing • how much • wasting time • how long • conveyor belt • manufacturing • excess motion • Related articles:
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