SCRAP REDUCTION STORY
Are you familiar with the problem of finding 25% of your muffins are burned, without sugar, or similar - and you cannot offer those to visitors? Consequently, you end up eating them yourself, even though they might not taste ideal, and scrapping them this way may not be too beneficial for your shape. This is what we call a problem statement.
Now, let's move forward by visualizing the different types of scrap using the Pareto principle. You will go through measuring scrap, visualizing, analyzing, investigating it, while our scrap reduction approach ensures your muffins are highest quality. You might eat even more.
Are you grappling with high scrap levels? Scrap is a wastage of money, resources, and materials during production and transportation. It can ruin your lead times and service level.
The following step-by-step approach for scrap reduction has proven highly beneficial in consultancy and coaching.
DMAIC serves very effectively as reliable framework for scrap reduction initiatives. DMAIC fosters systematic problem solving and sustainable results.
To facilitate the practical application of DMAIC, we have compiled the essential elements for scrap reduction. Learn more about how to use DMAIC for scrap reduction.
To begin, we recommend setting up a project charter. Utilizing a project charter helps the project leader gain clarity on crucial elements, such as:
To ensure accurate scoping of the project right from the start utilizing SIPOC greatly enhances the chances of success.
At the outset of any improvement project estimate the business case to determine the project’s value. Is the scrap project worth pursuing?
Use our bucket list to put together your business case:
The result of this must be something in a currency.
Many insights will come from tracking the scrap rate over time to study its evolution and variation. Work with trend charts. Display visually the most common types of scrap. Use Pareto. Pareto Chart will point out the main contributors to scrap generation.
When dealing with scrap problems, it becomes necessary to dive deeper into the realm of process variation. Scrap issues often arise due to common cause variation rather than due to special causes. But heads up: Attempting to address a common cause problem using a special cause approach has proven to make scrap rates worse. The concept of common and special cause variation can be intuitively understood by anyone, even without extensive data analysis.
Process capability should be enhanced to address common cause problems and minimize deviations. Does your team have to work with Cpk or Ppk to gain new insights into the process?
Working with Fishbone/Ishikawa diagrams broadens the perspective to not oversee potential root causes and to collect potential root causes systematically. Narrowing down the potential root causes is usually a straightforward task.
If human error is identified as one of the primary root causes, adopting the principles of Poka Yoke can significantly contribute to improvement. By employing Poka Yoke, you can enhance processes, systems, and designs to minimize the likelihood of human errors, thereby improving overall performance.
In the final stage of the project, building upon DMAIC, it is essential to visualize and monitor the chosen metrics to validate success or initiate a new iteration. Visualizing and observing the selected metrics helps gather insights into the effectiveness of the implemented improvements, ensuring that the objectives are achieved. This feedback loop triggers continuous improvement.
Engage your team for scrap reduction.
Our Yellow Belt Training "How to reduce scrap" conveys the required skills and empowers your team to drive impactful change.