Significant savings by focusing on process management and waste disposal (Part 2)

In order to save production costs, it is necessary to pay attention to the origin of scrap (to implement input solutions) and how to treat them (output solutions).

Returning to the example of a metal manufacturing company, after 3 months of applying the intelligent management software of InfinityQS, the company has changed significantly. The bottlenecks in the process are resolved in turn. Starting from the awareness of the workers, until the technical errors that cause waste. By understanding the core causes, improvements are made more thoroughly. The coordination between the areas in the factory also became more smooth leading to improved productivity, product throughput increased by 54%.

If you solve a big knot, removing the small ones will become easier. Here, the big bottlenecks are the reason for the high proportion of scrap. Solving this problem also means finding a solution to the problem of ensuring profits from raw material costs. Besides, the pressure from a large amount of scrap waiting to be treated also decreased significantly.

However, the amount of scrap inventory is also a problem. Regardless of whether they are sold or recycled, they should be sorted to separate raw metal from mixed scrap metal or multi-material waste and provide appropriate treatment. To do this, after finishing the process, the scrap should be preliminarily eliminated according to the characteristics of each line. Thanks to this, when the warehouse is stored, the management staff saves a lot of time for the sorting process, the scrap will soon be processed and soon returned to the organization’s working capital cycle.

As you can see, a factory can achieve such astonishing results just by collecting, analyzing and acting on the data collected, imagining what your organization can do. The problem of productivity – quality, the problem of cost – profit and the improvement problem can have the same solution. It is important that you know what you have, understand what you need and know where to start. By doing that, your organization will quickly show incredible potential.

The story of scrap is just a small corner in a big picture. Are you ready to unleash your potential at your organization?

Productivity and Quality Office