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Measure of Process Waste

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  • #37695

    Unsure
    Member

    Dear all,
    I am currently wrestling with how to best measure the value of process waste in a psuedo printing firm. We take 3 or 4 raw materials and “stick” them all together . Once they are joined we then cut them down to size to suit the customers orders. the problem occurs at the final cutting stage as it is only at this stage do we realise the full extent of the previous steps non conformance. Our current process of capturing this is to measure the level of input of raw materials say 100 then measure what we get out at the finished goods stage say 75.  The difference between the periods input minus the periods output is the waste figure, in this example 25.
    Is this the optimum way or does someone out there have more practicle ways ??? We seem to have loads of problems having reliable data, it is very reliant on manual imputs.

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    #111441

    Whatsinaname
    Member

    Ratio of good vs. ratio of total  is a good way of measuring  the waste percentage. You might want to check the credibility of the measurement system- Do a Gage R/R make sure the gage that you are using is accurate.

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    #111817

    R. Geiger
    Participant

    An additional point:
    You need to be very careful when collecting attribute data on your defects.  When you finally develop a method for capturing your data, you must make every effort to make sure that you can trust the data to get to the root cause of the defects.  Using MSA, (measurement systems analysis) can “calibrate” your inspectors so that you can be more certain that they are, #1 calling the defect by the correct defect code, #2 that they can reproduce that judgment, #3 that the entire inspection department agrees with each other.  Until you can calibrate all parties making judgments on defects, you cannot begin to successfully zero in on your problems.

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    #111819

    Perryman
    Participant

    Dear Unsure,
    It seems to me you have to figure out what it is you want the data to tell you before you go out and measure.  You already seem to say that measuring is not easy so don’t waste time and effort on it if it won’t help you to identify the critical X’s in your process.  You already have data on your process output, you say it yields about 75%.  What you need to measure is related to the key input variables.  I suspect you should be looking on getting data on the process steps you described upstream.  How are they “mixing” and what are the conditions of this process?  You might be better served by tapping into the organizational knowledge before going out and measuring.  They will tell you where to look for the most likely root causes…
     
    Good luck,
    Patch

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    #111992

    Venkatesh Yerramalla
    Member

    Dear Friend,
    In my opinion you need to give some details about your process to make a good suggestion. However in my opinion merely measuring yield may not give correct picture, as such you need to categorize the process waste or loss into various categories like end cuttings (generated when you cut the material to meet customer sizes), improper sticking, damages, etc. then start measuring against these categories, this would allow you prioritize the vital causes for loss and initiate appropriate corrective and preventive actions

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    #112268

    Adnan Basrawi
    Participant

    Dear all,
    I believe that the real waste is the difference between the optimized cuts and the output. The optimized cut would include opportunity lost (material loss) if other factors are adjusted (other factors would be such as delivery date, machine capability,etc 

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