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Resource efficiency: cut costs in plastics processing

Resource efficiency: cut costs in plastics processing. Workbook 3: supervising resource efficiency. Workshop objectives. To begin a structured review of waste quantities and costs To learn how to map a process using process flow sheets

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Resource efficiency: cut costs in plastics processing

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  1. Resource efficiency: cut costs in plastics processing Workbook 3: supervising resource efficiency

  2. Workshop objectives • To begin a structured review of waste quantities and costs • To learn how to map a process using process flow sheets • To provide a toolkit to help you reduce costs and improve environmental performance • To train you to train others Waste is anything that does not add value to the product Supervising resource efficiency 1

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

  5. Where to find waste • Incoming materials • Stores (raw materials, parts, final products) • Production • Support services • Energy • Water • Other Supervising 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 Supervising resource efficiency 5

  7. Tools for resource efficiency Worksheets: Roll out • Opportunity checklist Assumptions • Waste tracking methods Material waste: process flow sheet Method waste: cycle time flow sheet Focus on Pilot Measure key issues action success Supervising resource efficiency 6

  8. Material waste: process flow sheet Supervising resource efficiency 7

  9. Developing a process flow sheet Use the material and samples provided to generate a process flow sheet Supervising resource efficiency 8

  10. Adding detail to the process flow sheet OTHER OTHER Storage INPUTS OUTPUTS Rejected material Release agents MAIN INPUT Wasted time Labour Heating and lighting Transit packaging Plastics Dirty oil Utilities processing Purging materials Sprues and runners Lubricants MAIN Tops and tails OUTPUT Cleaning materials Heat Packing and warehousing warehousing Supervising resource efficiency 9

  11. Adding detail to your flow sheet Use the material and samples provided to generate a detailed element of your process flow sheet Supervising resource efficiency 10

  12. Opportunities for saving money: major sources of waste Name: Date: Sheet: of Process description: Process or Type of waste Estimated Estimated cost Current waste activity amount of waste including reduction produced per disposal, raw activities week/month/ materials, year purchase costs, utilities, added value per week/ month/year Net annual cost Extending the process flow sheet Supervising resource efficiency 11

  13. Addcost Activity Add value (waste) Moving Storing Plastics processing Counting Inspecting Scrapping Reworking Assembling Sorting Method waste Supervising resource efficiency 12

  14. The conventional factory: time in the system = 100 Value adding activities Wastes Towards the waste-free factory: time in the system = 33 The cycle time flow sheet • Process flow sheet that also records: • Activities that do notadd value to the product • Waiting times beforeand after processes • Distances travelledin the process Supervising resource efficiency 13

  15. Real cycle times • Use the form provided to determine your method waste efficiency ratio • Method waste efficiency ratio (%) = • time spent adding value • time spent adding cost Supervising resource efficiency 14

  16. How to reduce material waste Take action in the following areas: • Material management • Waste management • Energy management • Water management • Packaging management • Other measures Supervising resource efficiency 15

  17. 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 Supervising resource efficiency 16

  18. Five steps for quick savings 1. Collect the information 2. Identify the best project 3. Obtain management approval for the project 4. Plan the project 5. Make the first savings Supervising resource efficiency 17

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