Projects

Determining and calculating the amount of scrap of all kinds inside the factory

Determining and calculating the amount of scrap of all kinds present inside the factory and linking them to performance measurement rates | Reducing the waste of main materials during the manufacturing process by 5%.

Problem Statement:

After analyzing the factory's expenses, it was found that the largest portion of expenses was being spent on purchasing raw materials for the manufacturing process, which did not match the output of the final products. Therefore, the goal was to analyze the process of consuming raw materials within the factory and regulate it.

Goals:

·        Tracking and accurately calculating the scrap generated during the production process.

·        Analyzing the causes of scrap.

·        Reducing the total amount of scrap by 5%.

·        Calculating the cost of scrap before and after reducing it.

Application:

·        Identifying areas where scrap occurs, analyzing the causes of scrap and restarting.

·        Training engineers, technicians, and workers on the optimal method of executing production and manufacturing processes with minimal scrap and defects.

·        Developing a preventive maintenance plan for machines and equipment to reduce material waste.

·        Establishing and activating the quality management cycle to record, track, and measure defects and scrap.

·        Creating standard operating procedures for operations and machines to reduce machine setup and operation time (where the largest amount of material waste occurs)