5 Side Effects of Poor Layout in your factory?
How Transportation Waste affects your Productivity...
1 Article for the week:
Transportation is one of the major wastes in a shop floor. It also has a lot of Side Effects. These side effects are more dangerous than the Transportation waste itself.
Transportation means moving the product from one location to another location. There is no value addition during this movement.
Side Effects of Transportation:
1. Batch Production: Since the machines/process are at a distance from each other, Continuous Flow / Single Piece Flow is not possible. Now, we need bins / storage systems as we produce in batches and move them.
2. Material Handling Systems: Since the product is moved in bins, we need to have material handling equipment like Conveyors, Forklifts, trolleys, etc - which are expensive, occupy space and require manpower to operate
3. WIP: Batch Production leads to overproduction resulting in high Work-In-Progress and takes a lot of space.
4. FIFO: When we have a high WIP, following First-In-First-Out is a challenge, leading to deterioration of Quality
5. Fire-Fighting: High WIP creates a lot of confusion in the shop floor and this leads to poor productivity, Parts mixup, rejections, etc
Do you find Transportation waste & it’s side effects in your shop floor? Share in the comments.
2 Quotes for the Week:
“Live as if you were to die tomorrow. Learn as if you were to live forever” - Mahatma Gandhi
“Education is teaching our children to desire the right things” - Plato
1 Image for the week:
Dear Ananth, yet another wonderful article and you have covered all the points very well. The maintenance of the MHEquipment is an additional ocst, for skilled technicians and downtime.
Another aspect is I come from an Auto industry and was at the shop floor of the Press Shop. The Press shop knew only Batch production, as the Presses available were far less than the number of parts being produced. Yes we would then monitor the FG qty and schedule the next batch about 4-5 days before the expected consumption date. I guess it is the same situaiton at other Auto manufacturers too.
Please share your views, you can use the above example as a question and share your views.
Kind regards,