Scrap reduction in manufacturing

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Do you have issues with quality?
How can you improve this?
Start by targeting SCRAP
Scrap tracking allows you to…
Understand reasons for your rework and rejects
Determine actual costs
Target the worst offenders and direct resources at key areas

Speak to our team today
T: +44 1642 370666
E: sales@tascomp.com

Improving Quality – Reduce Scrap & Rework
Poor quality production, scrap, rejects, rework, spoilage, give away and overfilling are all types of waste that reduce manufacturing efficiency. PlantRun systems can monitor quality and count scrap product during production to provide real-time quality KPI’s, reports and alarm if scrap target levels are exceeded.
PlantRun can accept a count of reject, defective or scrap product or connect to thousands of different industrial measuring and monitoring devices for automated quality checking. Alternatively scrap data can be input manually or via spreadsheet at any time.
Capture reasons for scrap or poor quality
PlantRun can also capture reasons for scrap or poor quality. This means you not only know how much scrap product was made but also why, providing valuable information to target and improve quality.
This can also be used to record at what point during manufacture the product was scrapped with a higher value (or loss) being assigned to it the later in production this occurs.
Furthermore and unlike most OEE systems, PlantRun can also handle any process values (temperature, pressure, humidity etc.) that may be critical to the quality of your products as well as provide any level of control that may be required.
Monitoring of scrap and rework can be as simple or sophisticated as you need to inform you of;
• Scrap variance against target or planned scrap
• Nominal cost of scrap for any job or production run based on costing values for raw materials, energy, labour rates etc. input to the system.
• Scrap, rework and spoilage against any monitored parameter. This highlights differences in scrap and rework levels by product, shift, operator, raw material, machine etc.
• Giveaway or over filling count or weight
• Yield, based on inputs and outputs
Automated Quality Checks
Where regular quality checks are required during the manufacturing process PlantRun can alert when these need to occur, typically based on number of products made or timed intervals. PlantRun can also stop production if a quality check has been missed or have the interlock facility disable production being restarted until the quality check has been undertaken. The system can record the time and details for each quality check making them available as live and historic data that can be distributed, analysed and reported or exchanged with third party systems.
Jidoka and PlantRun
In Lean Manufacturing and Just in Time (JIT) manufacturing environments PlantRun can be used to enable the Jidoka technique as used in the Toyota Production System (TPS).
With Jidoka when poor quality product is detected production is stopped. Special attention is given to not only fix or correct the immediate problem but to also investigate the root cause and introduce measures to ensure the problem does not reoccur – in line with poka-yoke mistake proofing.
Jidoka prevents scrap and rework, eliminates overproduction and reduces the amount of work that is added to a defective product.
By using PlantRun wherever possible to monitor product quality it can be used to automatically stop production when defective product is identified. This relieves the need for staff to continuously judge whether machines are operating normally. This can improve man machine ratio with staff focusing their attention on any problems that occur.
Although the Jidoka technique slows production when defects are found it reduces waste and improves efficiency by the early detection and rectification of problems. It is cited as a major factor in the difference between the effectiveness of Toyota and other companies that have adopted Lean Manufacturing.