yes. my project was to reduce rework cost and improve productivity. Through this project, we have also reduced the scrap in the company.

my article - REDUCTION OF REWORK COST IN MANUFACTURING INDUSTRY USING STATISTICAL PROCESS CONTROL TECHNIQUES: A CASE STUDY

A good time and resources Manager goes a long way to minimize cost and increase profit. I ensure this, in my own capacity, to help to promote efficient use of resources and talent. I participate in this by creating awareness, training, encouraging and living by example.

I don't eat processed food and I don't drink any cola since 10 years ago.

Thanks for your insight Segun Michael Abegunde and Pranay Sureshbhai Parmar

My project was to reduce unnecessary needs.

Taha Ahmed Abdullah do you have anything you can share?

@Taha Ahmed Abdulla

I find your comment pretty interesting.

You have earlier mentioned that you have worked on a project that was aimed at reducing Unnecessary Needs (UN).

Would you please elaborate the idea a bit further ?

In this connection, I would like to share my idea about UN. Quite often marketing people indulge in creating UN, in order to promote sales.

A small story to illustrate this a bit further. One fine morning a sales-man knocked at our house door and asked me whether I would be interested in buying a vacuum-cleaner from him. I informed that we already have one and are quite satisfied with the performance of our ten-year-old machine. At this point the sales-man came out with a "Brilliant" idea. He suggested, that he could arrange for taking the old machine in lieu of a corresponding discount on the new one.

In my opinion, the concerned sales-man in the above-mentioned example fails to realise that his proposal amounts to creation of an "UN".

In fact, creation of such Unnecessary Needs result in wastage of "National Resources", which is always scarce and needs to be used judiciously.

Taha Ahmed Abdullah just wondering if you have seen the message directed to you above from Ashis Ranjan Bandyopadhyay as the link to your name in his message doesn’t seem to have worked.

Hello

Carreira, B. (2005). Lean manufacturing that works: powerful tools for dramatically reducing waste and maximizing profits. AMACOM/American Management Association.

Ingrid

Thanks Ingrid Del Valle García Carreño very much appreciated. I will give this a read. Do you have a PDF copy of the document?

following the answers

Much was done to decrease scrap in chemical processing over 5 decades.

Interesting discussion, following

i am afraid, I don't understand the question and its expectation, please, give an example.

Between acting and the linguistic expression of this doing in reality is a big difference. You may reduce a sentence, but not reality.

Hein Retter the wastes I have mentioned are sometimes referred to as the 7 deadly wastes. Although, in this instance there is 9 as I have included talent and training.

Talent - Because there are a lot of talented people in organisations who are underutilised. One example - A company was employing manufacturing staff. One individual was employed who had 10 years experience spray painting cars. He was placed in engine assembly. Why would he not be placed in painting?

Training - Some individuals get placed on training courses which arent relevant to their area of expertise. So when they return from the course they can not implement what they have learnt.

Basically I am looking for practical examples of where people have actively reduced or eliminated these wastes from their organisation. Its a wide based topic but I was hoping something may land which could spark an idea in my head which I can then look to implement in my organisation.

Hope this helps, thanks for your contribution and to the other individuals who have commented on this post. Much appreciated.

A very small (but significant) non industry example.

I reduced my domestic garbage disposal by starting HOME COMPOSTING. So my daily disposal now, does not contain fruits/vegetable peels and used tea leaves/bags.

I am on to my second batch.

Two other neighbours have also joined in.

virendra

Virendra kumar Gupta great example. I’ve actually got another question which I’ve asked people to detail what they are doing personally to enrich the environment / reduce waste. This is a perfect example.

In the area of transport - car pooling is something we have done. Another area is water - rain water harvesting is a very practical way to save water

Thanks Martin, I feel encouraged.

VKG

I can also add examples from my industry experience-(usually because we do not keep any notes, we cannot recollect.

One example I can quote-of course quite an old one was reduction of rejection in a plastic injection molding unit.(dates to around 2005).The target and the achievement was around 5-6 %. After i became a consultant for process improvement, I questioned the target. But most of them were satisfied. WE followed the typical way of data collection, stratification and analysis. Three major products were selected for further work-again data analysis , C& E diagram etc.. All steps as per the improvement methodology were followed.

In about a year and a half, this was brought down to about 1 %.

Subsequently, by suitably improving the molds designing process this was steadied at about 0.6 % in a total of about 2+ years.

I can describe further details if you require.

KR

Virendra

Thanks Virendra kumar Gupta and Tabitha Durai for your contributions. Much appreciated.

Hello Martin,

Incidentally, my second batch of home compost has come out exceeding well. I am going to send it for test on Monday.

But I feel there should have been better response from readers.

KR

Virendra

Interesting discussion! Following.

Dear Martin,

Please look at the one of the paper we have published. Work was conducted at mesfin Industry.

REST Journal on Emerging trends in Modelling and Manufacturing 2(1) 2016, 1–9, Website: www.restpublisher.com/journals/jemm

Ashish

HELLO ASHISH,

WHICH PAPER ARE YOU REFERRING TO?

PL MAKE SURE, IT IS RELEVANT TO THE ABOVE TOPIC.

Virendra

Dear Gupta Sir,

Yes. You can go through the paper. I have supervised one of my product design student working in Mesfin industrial engineering(currently he is in China) and MAA garment industrial engineering, and another student currently pursuing doctorate in Belgium worked together for their research on waste removal.

Hope it help you out.

Ashish

Virendra kumar Gupta thank you for the information you have provided, much appreciated.

Ashish Thakur thank you for your contributio, much appreciate.

Hello Ashish,

Either I am dumb or you are confusing me.

I tried to access the [a[er by going to the site and the journal as specified by you. But where is this paper you are referring to?

Can you just upload the paper in some way so I do not have to spend time and effort as I have already done? Help your 'customer'.

Virendra

I have a case in an electrostatic aluminium painting factory where we mainly work on;

1- Waiting

2- Movement

3- Over processing

4- Talent

The objective is to increase the productivity of the factory by at least 5%. Our current study implies that we can reduce the Cycle time/ton of one of the operations by 30%. The solution depends mainly on the removal of the waiting time by redesigning of the layout.

Scrap reduction- virtual prototyping (VR simulations) and precision machining akin to 3D printing, the WYSIWYG equivalent in engineering of what was desktop publishing. 100% reproductions of ideation. Reducing the multiple prototyping and iterations to arrive at the "finished product". Trade-offs between robustness scrapping . Combining case-based reasoning with CAD systems; and theorizing what constitutes "ingenuity" in virtual and real production:

Article Prediction of total manufacturing costs for stamping tool on...

Article The Open, the Closed and the Emergent: Theorizing Emergence ...

Shian-Loong Bernard Lew and Mohammad Amr Abd Elkader thanks for your contributions.