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Resource efficiency: cut costs in plastics processing

Resource efficiency: cut costs in plastics processing. Workbook 4: operating resource efficiency. Not: stop waste ! But: find waste !. The greatest waste is the waste we don’t see. Operating resource efficiency 1. Business pressures for resource efficiency. Waste costs real money

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Resource efficiency: cut costs in plastics processing

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  1. Resource efficiency: cut costs in plastics processing Workbook 4: operating resource efficiency

  2. Not: stop waste!But: find waste! The greatest waste is the waste we don’t see Operating resource efficiency 1

  3. Business pressures for resource efficiency • Waste costs real money • The true cost of resource inefficiency and waste is hidden • Resource efficiency is good business • Legislation and the legal consequences • Our reputation and customer pressure Operating resource efficiency 2

  4. Words for waste • Conveyor loss, customer returns … • Defects, dirty solvent, dregs, dross, dust ... • Obsolete stock, offcuts, out-of-spec, overfill … • Reel ends, regrind, rejects, rework, rubbish … • Scrap, second quality, sprues, sweepings … • Usage allowance, usage variance ... • Workaway, yield loss ... + more that are being invented all the time Operating resource efficiency 3

  5. Where to find waste? • Incoming materials • Storage (raw materials, parts, finished products) • Production • Support services • Energy • Water • Other Operating resource efficiency 4

  6. What to do with waste? Eliminate it Best and cheapest Reduce it Re-use it Recycle it Dispose of itWorst and most costly Operating resource efficiency 5

  7. OTHER OTHER Storage INPUTS OUTPUTS Rejected material Release agents MAJOR INPUT Wasted time Labour Heating and lighting Transit packaging Plastics Dirty oil Utilities processing Purging materials Sprues and runners Lubricants MAJOR Tops and tails OUTPUT Cleaning materials Heat Packing and warehousing Process flow sheet Operating resource efficiency 6

  8. Addcost Activity Add value (waste) Moving Storing Plastics processing Counting Inspecting Scrapping Reworking Assembling Sorting Method waste Operating resource efficiency 7

  9. The five whys • Get to the root cause of a problem • Ask ‘why’ at least five times • Remove the root causes - not just the visible symptoms Operating resource efficiency 8

  10. Cause and effect diagram (the Ms) Environment Machines Materials Effect Men Measures Methods Operating resource efficiency 9

  11. How to reduce material waste Take action in the following areas: • Materials management • Waste management • Energy management • Water management • Packaging management • Other measures Operating resource efficiency 10

  12. How to reduce method waste • Reduce stocks and work-in-progress • Improve worker involvement and quality • Increase flexibility and productivity • Choose the best machinery • Reduce lead times dramatically • Add value not cost • Improve workflow Operating resource efficiency 11

  13. Potential opportunities Operating resource efficiency 12

  14. Potential opportunity analysis • What is the real cause of the concern? • What information is needed? • What are the available sources of information? • What do we need to fill in the gaps? • How are we going to get it? Operating resource efficiency 13

  15. Operator contributions • Vital understanding of how processes actually work • Day-to-day contact with the process • Hands-on ability to reduce waste and improve resource efficiency Operating resource efficiency 14

  16. Operator opportunities • Contribute to the business • Increase job satisfaction • Gain experience in problem solving • Increase understanding of their job Operating resource efficiency 15

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