Waste Analysis on a Production Line - A Case Study

Abstract

This study aims to assist Swedish company Clemondo AB in reducing waste in production, where the goal is to determine where waste appears as well as make suggestions for potential improvements, which are presented as Key Performance Indices (KPIs) and minimized manufacturing costs. Citation chaining is used to retrieve extant literature, while other productions and process-related information are gathered through observations and discussions. The production and its value-creating activities are modeled through Environmental Value Stream Mapping (EVSM). Factors causing downtimes and other waste are identified via a Production Performance Matrix (PPM). The results show that actual production times differ from the planned times, which causes waste in terms of time consumption and energy consumption. Moreover, downtimes are present and are normally caused by the same factors. Wasted materials in terms of blend spillage and discarded packaging materials are also present in production. All waste ultimately increases the manufacturing cost, and it is concluded that the company spends approximately 13 000 SEK more on each batch production due to existing waste. In order to optimize production, and specifically to reduce waste, four KPI measurements are suggested for the company: (1) measuring all times in production including occurring downtimes, (2) frequently calculating OEE, (3) tracking material spillage, and (4) measuring energy consumption. Potential future studies include further investigating other areas in production where waste may be present, as well as continuously doing follow-ups to see how changes affect waste optimization.

Abstract (Swedish)

Denna studie har syftet att vägleda det svenska företaget Clemondo AB i att minska på avfall och annat slösande i deras produktion. Detta fullföljs genom att fastställa vart avfall och slösande uppkommer, samt genom att ge förslag på förbättringar, vilket presenteras i form av Key Performance Indices (KPIs) och i minskade produktionskostnader. Citation chaining används för att hämta befintlig litteratur, medan annan produktions- och process-relaterad information samlas in genom observationer och diskussioner. Produktionen och dess värdeskapande aktiviteter modelleras genom Environmental Value Stream Mapping (EVSM). Faktorer som orsakar stillestånd och annat slöseri identifieras via en Production Performance Matrix (PPM). Resultaten visar att faktiska produktionstider skiljer sig från de planerade tiderna, vilket orsakar slöseri i form av tids- och energiförbrukning. Dessutom finns driftstopp som normalt orsakas av samma faktorer. Avfallsmaterial i form av blandningsspill och slängt förpackningsmaterial förekommer också i produktionen. Allt avfall ökar tillverkningskostnaden, och slutsatsen dras att företaget spenderar cirka 13 000 SEK mer varje produktion på grund av befintligt avfall och annat slöseri. För att optimera produktionen, och specifikt för att minska avfallet, föreslås fyra KPI-mätningar för företaget: (1) mäta alla tider i produktionen inklusive förekommande stilleståndstider, (2) kontinuerligt beräkna OEE, (3) spåra materialspill och (4) mäta energiförbrukningen. Potentiella framtidsstudier inkluderar att ytterligare undersöka andra områden i produktionen där avfall kan förekomma, samt att kontinuerligt göra uppföljningar för att se hur förändringar påverkar avfallsoptimeringen.

Popular Abstract

A manufacturing company wastes millions of SEK annually due to unnecessary practices. How is the company supposed to minimize these costs and become the most coveted company on the market?

Our study analyzed waste on a production line to help a company become more green. We found that the most waste comes from recurring disturbances. These disturbances cover unnecessary downtime, energy consumption, and insufficient planning ... to name a few. Operators are left waiting for the next task to come along, and as the saying goes; time is money! The company spends 13 000 SEK extra each batch due to waste, which leads to millions of SEK being wasted each year. To avoid this, simple measurements can be implemented in the system, which will lead the company to where the grass is greener on the other side. Not only will this save them money, but it is also good for the environment! By limiting the material littering, our planet can flourish.
We can think of production as a recipe. Based on our study, the key ingredients are simple. To promote more sustainable production, accurate documentation of the production in the form of protocols makes planning more efficient and leaves room for optimization. Tracking how and when materials are discarded during production is another ingredient. This helps with exposing what practices need to be changed to promote green work habits. The last ingredient is measuring the energy consumption. Some scenarios in our study indicated longer production time, and it could be beneficial to establish how much this affects energy consumption. To see any issues in production, it would be well-fitting to measure the consumption of every production.
Having these ingredients as your mise en place, you can cook up the recipe for optimal equipment efficiency and be full and satisfied, knowing that the company is in good and green hands.
The results were found using lean thinking when observing the production facility, as well as through deep and informative discussions with employees. Consulting with the managers of the company, they believe in implementing these lean methods into their production system. In the future, we predict that these improvements can save the company millions in production costs.
We hope this stimulated your interest to read our whole study. Perhaps it motivates you to adopt a leaner mindset, or perhaps it serves as a lesson for your future business. Every company should strive to leave an environmentally sustainable footprint, and by implementing our recommendations, a company may be able to do just that.

• author: Treptow, Sanna and Karida, Déspina
• supervisor: Christina Windmark
• organization: Production and Materials Engineering
• course: MMTM05 20231
• year: 2023
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Sustainable manufacturing systems, Sustainable production, Lean production, Just in Time Production (JiT), Kanban, Waste, Environmental Value Stream Mapping (EVSM), Production Performance Matrix (PPM), Key Performance Index (KPI)
• report number: CODEN:LUTMDN/(TMMV-5347)/1-111/2023
• language: English
• id: 9123444
• date added to LUP: 2023-06-12 11:51:49
• date last changed: 2023-06-12 11:51:49