11 Simple Tips to Prioritize Errors and Waste in Production
Adebayo Olanrewaju CSSMBB™, MNSE, R. Engr
Founder at Olanab | Consultant/Trainer: Digital Manufacturing, ISO Management Systems (ISO 9001, ISO 22000...) & Process Excellence | Lean Six Sigma Master Black Belt | COREN Registered Engineer, AMIChemE, AMNIM
The process of manufacturing or producing a product involves several stages and a multitude of steps. With such intricate processes, errors and waste are bound to occur. In order to improve production efficiency, reduce costs, and guarantee the quality of the end product, it is essential to prioritize and address these issues in a structured manner.
This article provides insights into the best practices to prioritize errors and waste in production.
1. Understanding the Difference: Errors vs. Waste
Errors: Mistakes or faults that deviate from the standard or expected outcome. They can be defects in the product, incorrect measurements, or incorrect operations.
Waste: Resources that add no value to the end product. This could be in the form of raw materials, energy, time, or even human efforts.
2. Classification Using the 8 Wastes of Lean Production
Lean Manufacturing identifies eight types of waste: defects, overproduction, waiting, not utilizing talent, transportation, inventory excess, motion waste, and excess processing. Classifying your issues within these categories can help in recognizing and addressing them systematically.
3. Prioritize by Impact on the End Product
Errors and waste that directly impact the quality of the final product should be addressed first. This could be defects that make the product unsafe or unsellable.
4. Evaluate the Financial Implications
Understand the cost implications of each error and waste. Those that result in significant financial loss, either due to waste of materials or potential recalls, should be high on the priority list.
5. Assess Frequency and Repetition
Errors and waste that occur frequently indicate a systemic issue that needs urgent attention. Even if individual occurrences seem minor, their cumulative effect can be substantial.
6. Consider Lead Times and Customer Commitments
Issues that can cause delays in delivery times or breach agreements with customers should be swiftly addressed to maintain reputation and customer trust.
7. Feedback from the Production Floor
Often, the team directly involved in the production process is the first to notice inefficiencies. Regular feedback sessions can help in early identification and prioritization.
8. Customer Feedback
Issues raised by customers post-sales, such as defects or functionality issues, should be high-priority, as they impact brand reputation and customer satisfaction directly.
9. Ease of Resolution
Some issues might be easy to solve with quick fixes. Addressing these can provide immediate improvements and motivate the team by showing progress.
10. Implement Preventative Measures
Once errors and waste are identified and prioritized, work on implementing measures to prevent them from reoccurring. This could involve training, process changes, or even machinery upgrades.
11. Continuous Monitoring and Review
Set up regular audits and reviews to assess the production process. With changing dynamics, new issues may arise, or old ones might resurface.
Conclusion
Errors and waste are inevitable in production. The key is not just to address them, but to do so in a manner that brings the most value to the organization. By understanding, classifying, and systematically prioritizing these issues, businesses can optimize their production process, ensure high-quality products, and maintain a competitive edge.
What other tips do you suggest, kindly share with us in the comment section.