In an era of complex business challenges; intense global competitiveness, burdensome environmental regulation and resource constraints, companies need both lean and green (clean) manufacturing technology to eliminate multifaceted manufacturing wastes in production operations.
All forms of manufacturing waste significantly impact profitability. So why let these preventable wastes steal your company's hard-earned profits?
What is Manufacturing Waste?
Manufacturing waste is any resource used in a production process that does not go out as part of the product or is unnecessarily used (or misused) to produce a product. Manufacturing waste is defined differently for every business, however, it has the same underlining message. If the process is non-value adding and costs you money but earns nothing for your business then it is a waste.
Eight Deadly Wastes of Manufacturing
There are eight major forms of manufacturing waste that impact manufacturing profitability. Manufacturing wastes include for example lost time, high energy usage, excessive labor, poor product quality, low productivity, too much factory space, scrap, and stock levels. These wastes steal company profits. To stay competitive, companies must implement programs that reduce or eliminate these wastes.
Overproduction waste is costly to a manufacturing operation because it prohibits the smooth flow of materials and degrades quality and productivity. Motion waste processing time and is a health and safety concern. Defect wastes have a direct impact on the bottom line, resulting in rework or scrap which are a tremendous cost burden to an organization. Transport waste is excessive movement and handling which causes damage and defects and can cause product quality to deteriorate. Environmental waste such as energy or water use, solid or hazardous waste, air pollution, or chemical hazards are typically overlooked when in fact they impact the bottom line and surrounding communities. Inventory waste tends to hide other waste generation activities on the plant floor, which must be identified and resolved in order to improve operating performance (and cash flows). Waiting waste is whenever goods are not moving or being processed and a product lead-time is tied up – time is money. Processing waste is using expensive high-precision equipment or processes where smaller footprint, more flexible, and less precision equipment and processes can combine steps which would be more efficient – the enemy of good enough is better than.
Lean and Green Manufacturing
CO2 Technology is the New Manufacturing Model
The manufacturing waste radar chart (shown right) illustrates an exemplary manufacturing waste generation transformation (Old versus New state) using our CO2-based clean manufacturing technology. Notice that the area bounded by the various waste generation activities becomes smaller with the implementation of clean manufacturing methods and processes. Smaller waste generation activity represents a cost reduction or profit improvement for the transformed production process, tool, or line.
Our CO2-based clean manufacturing technology provides the following benefits:
- Simultaneously eliminates or reduces composite forms of manufacturing waste: time, labor, space, transport, defect, inventory, processing, equipment, raw materials, air pollution, water pollution, wastewater, solid waste, and energy waste.
- Improves quality and reliability requirements imposed by advanced materials, manufacturing methods and processes, and applications.
- Uses flexible automation, modular and clustered assembly operations (cells) to eliminate repetitive operational task errors and reduce skilled labor wastes.
- Adaptable to production tools, lines, and processes to improve efficiency and productivity in variable-volume, high-mix, and high-value production operations.
- Flexible and scalable to changes in production needs over time.
- Intelligent, autonomous, and capable of communicating key information in real time that enhances manufacturing quality, timeliness, and productivity.
- Produces a low cost-of-operation and good return-on-investment.
The lean and green clean manufacturing model using CO2 technology combines advanced surface cleaning, surface cooling, and surface modification technologies and robotics technology to provide multi-tasking manufacturing processes for a production line, in a manufacturing tool, or within a reconfigurable cell.
As shown in the exemplary comparison on the right, the clean manufacturing model provides the basis for huge returns in the form of less labor inputs, less space, less energy usage, less time waste, less water usage, among many other waste reductions.