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Waste Reduction in Technical Ceramics Manufacturing Plant
Consultant
RPM is a Mechanical Engineer, Quality And Manufacturing Management Executive, Manufacturing Process Engineering Consultant, Technical Ceramics Manufacturing Expert, Quality Assurance Specialist, Outsourcing and Offshore Manufacturing Consultant with world-class expertise in quality management, mechanical engineering, offshore manufacturing, quality audits, technical operations, technical training, project management, process involvement, manufacturing operations, process improvement, scrap reduction, multi-site operations, staffing, human resources, customer relations, supplier relations, turnaround management, reliability, QS 9000, QS9000 certification.
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Introduction:
Consultant at a Technical Ceramics manufacturing company that manufactures around 17 different types of Technical/Industrial ceramics products around 1000MT of steatite, cordierite, porcelain grades annually. The company also specializes in manufacturing custom made products as per customer specifications and requirements. Currently, the company's customer includes some of the fortune 500 companies and currently exports to more than 25 countries.
Problem:
The company was facing major problem of rejection of the product during its final stage resulting in significant raw material waste. This also impacted company's labor overhead and also increased the cost of solid waste disposal. The rejection was consistently coming at about 20% from Initial green stage manufacturing to final products. This consultant was consulted to study and implement a process that would help reduce their rejection rate resulting in significant cost savings.
Execution:
- Collected present Data of final rejection and analyzed the same using Pareto Analysis. (80/20 Rule - Cost wise and quantity wise). It was found that about 12 products were responsible for creating about 65% of the total waste. Those 12 products were chose to identify the areas that needed modifications.
- As an immediate measure until preventive actions are implemented, tighter inspection control were imposed at every level of manufacturing process. Backward integration was carried out up to the stage where rework is possible or material could be reused. For any ceramic product, it could be reworked or the raw materials could be reused before they are inserted in the kiln for heating. This resulted in rejection of the final products thereby reducing raw material waste.
- Next stage was to examine the defects causing reject and the possible source of the defects. All processes were critically examined at every stage of manufacturing process using Cause Effect Analysis. Production, Quality, Tool Room and Ceramist personnel were asked carry out root cause analysis. It was concluded that the hydraulic press at the pressing was creating one major type of defect that was contributing to major source of waste generation at final stage.
- Corrective actions were implemented immediately. The pressing cycle at hydraulic press was modified to prevent the defect formation at that point. Thus the source was eliminated. The modified press cycle was monitored for about month on day today shift basis to ensure that defect is prevented.
- Today, the waste has come down to below 10% and has resulted $250K in cost savings.
- After this study, as a result of continual improvement process, it was also decided to create a Team that focuses on improving Quality for further improvement and development of the manufacturing.
| Mechanical Engineer, Quality And Manufacturing Management Executive, Manufacturing Process Engineering Consultant, Technical Ceramics Manufacturing Expert, Quality Assurance Specialist, Outsourcing and Offshore Manufacturing Consultant, quality management, mechanical engineering, offshore manufacturing, quality audits, technical operations, technical training, project management, process involvement, manufacturing operations, process improvement, scrap reduction, multi-site operations, staffing, human resources, customer relations, supplier relations, turnaround management, reliability, QS 9000, QS9000 certification. | |
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