Running Head Waste Reduction

Development of Waste Reduction in manufacturing Industry

IndM4250
Project Management
Graduate Research Paper
By
Yasaswi Bobba
MS in Technology
Spring 2015
University of Central Missouri

Table of Contents

Abstract 03
Introduction .04
Basic ideas of waste reduction .05
Advantages of waste reduction 06
Disadvantages of waste reduction 07
How waste reduction is achieved? .08
Goals of waste reduction 09
Tools of waste reduction .09
Sources of waste in production process ...11
Keys to successful waste reduction .13
Selection of team .14
WBS .19
Critical Path .21
Conclusion ...23
References ..24

Abstract
At present situation, waste reduction has become a universal phenomenon. Municipal waste was
decomposed in three different forms. According to the year 2004 it was projected that 71% is
land filled, 16% incinerated and 13% recycled. Other types of wastes are from the nuclear and
hazardous wastes. In this paper we are discussing about the basic ideas of waste reduction and
the advantages and disadvantages of the waste reduction. Waste reduction is enhanced by
implementing the tools and techniques of the lean manufacturing. By implementing the waste
reduction in an organization helps in improving the quality of the product and enhances the
product durability. This paper also discusses about the tools that are used in the lean
manufacturing and their implementation in the manufacturing companies. This paper explains
the Work Breakdown structure and the resources which gives the clear idea about the project.

Introduction to Waste Reduction

The Solid Waste Management Act (RCW 70.95) defines waste reduction as reducing the
amount or toxicity of waste generated or reusing materials. Waste reduction is also known as
source reduction and waste prevention (Waste reduction manaual). Waste includes the items
which are not used any longer or which are to be intended to discard. Moreover, waste is an item
that people are required to discard for instance by lain due to its hazardous assets. Some of the
things which are considered as waste e.g., household garbage, sewage slurry, wastes from
manufacturing companies, discarded cars, old televisions, garden waste, food waste etc. Hence
our daily actions are giving rise to different types of waste from the different sources. Waste has
existed since the beginning of time. Earlier from the history the waste was decomposing
according to the natural cycle. Coming to the present scenario because of the industrialization,
drastic increase in population, change in the lifestyle, the issue how to collect, store and
decompose the waste was been increasing. Over 251 million tons of waste is generated each
year in United States of America. The waste is coming from the different sources such as
industries (pharmaceutical, manufacturing, textile etc.), agriculture, construction and mining
activities (Eionet, 2013).
Now in order to handle all these types of waste, to protect the environment and human
beings waste management came into scenario to resolve the issues existing due to waste. The
waste management has evolved with many concepts such as reusing, recycling, recovery of
energy, disposal, prevention, landfilling and minimization. The waste reduction has a basic idea
which has been followed all over the globe called as 3Rs in which mean reduce, recycle and
reuse of the waste being generated (Sheryl, 2008).

Basic Ideas of Waste Reduction

Reduce: Since we are generating the waste we must also think what the ways to make it less are.
By considering the better ideas on buying the products and goods, also by planning activities we
can minimize the waste production. We can reduce the waste production by using pre-cycling or
enviro-shopping (Willingham).
Recycle: Recycling is the process of transforming the waste materials or items into the usable
form of things for the future usage other than landfill disposing. Products like PVC, LDEP, PP
and PS are recyclable though they are not collected for the process of recycling. However,
complex products are difficult to treat for recycling. The programs of recycling are very
extensive and different in which the process melting of aluminum cans in to new cans, filtering
the used motor oil, turning plastics into carpet, yarn, and lumber (Waste reduction manual).
Reuse: Reuse is the process of using the product in its usual form more than a time. Examples
include replenishing glass bottles, recycling long lasting utensils, buying refurbished appliances
rather than purchasing new one. The Solid Waste Management Act (RCW 70.95) graded reuse in
the group of waste reduction.
The amount of waste and the distribution of waste can be observed in the following diagram.

Figure 1 (CIPS knowledge works, 2007).

Advantages and Disadvantages of Waste reduction
Advantages:
1. Protects Environment: One of the most important benefits of waste reduction protecting
the nature and environment in the balanced way. As the tress are cutting down
continuously paper which is coming from that certain tress leading to the deforestation to
avoid that paper recycling evolved out. The recycling paper is one of the example shows
that many natural resources can be reused.
2. Reduces the Energy Consumption: Lot of the energy was utilized in the industries while
processing the raw materials during the manufacturing process. By the process of

recycling energy utilization was reduced which plays a vital role in the enormous
production for instance mining and refining.
3. Reduces Pollution: Waste from the companies is the important source for all kinds of
pollution. Reusing the industrial outcomes such as chemicals, plastics help in reducing
the pollution.
4. Reduces Global Warming: Recycling and reusing helps in elevating the global warming.
Lot of waste was burned in the heaps which releases the toxic gases such as CO2 and
CFCs. By using the recycling process burning process in reduced and there will be less
impact on the nature.
5. Create Green Jobs: Recycling and reusing is very good to the environment and also it
creates green jobs. As per to the U.S. Bureau of Labor Statistics, green goods and
services accounted for 3.1 million jobs in the United States by 2010 (Conserve Energy
Future).
Disadvantages:
1. Not always Cost Effective: Recycling and reusing, both were not always cost-effective.
Sometimes they are needed to establish a separate company to process the reused
products. As it goes to the many stages of processing procedures such as cleaning, storage
and transportation it creates more pollution.
2. Recycled Products May not Last for Long: As the recycled products are made from the
trashed items, and also from the other waste outcomes which are mostly fragile so the
recycled products are less durable, cheap and last for the shorter period.
3. Unsafe and Unhygienic Recycling Sites: As the waste was dumped at one place there will
be a chance of forming debris and spreading the dangerous disease so the recycling sites
are mostly unsafe and unhygienic. This not only spreads wide range of pollution it may
also damage the health of the people who are recycling the waste products. When such

kind of waste is mixed with the water it forms the leach which leads to the toxic release
in water.
4. Not widespread on Large Scale: Recycling and reusing were the important in minimizing
the pollution but it was a long term achievement. Mainly the concepts of recycling and
reusing were occurring at schools and small scale industry sector it fails in implementing
in the large scale industries.
5. High Initial Cost: To set up a recycling plant it involves very high cost. This high cost is
upgraded from the various sources such as processing facility, educating residents by
organizing seminars and other programs, disposing of existing waste and chemicals etc
(Conserve Energy Future).
6. Average person in UK produced 510kg of waste in 2004 - composting only reduces this
by 170kg, the rest still needs to be dealt with.
How waste reduction is achieved?
Waste reduction is achieved in four ways:
1. The best and foremost way to achieve the waste reduction is by minimizing the
consumption.
2. The second way is by reusing the product outcomes and materials.
3. Waste reduction can also achieve by raising the durability of product.
4. And also by minimizing the usage of the resources which are used to develop and market
products mainly the packaging (Waste reduction manaual).
Goals of Waste Reduction

Decreasing per capita unwanted waste group.

Changing the customer thoughts in purchasing the goods which they have less packaging

and more quality.

Minimizing the packaging material by the manufacturer of the company.
Decreasing the weight of the product.

Improving the quality of the product and the reusability.

Generation of waste can be decreased by improving the quality and effectiveness during

manufacturing.
Vermicomposting is one of the best technique which helps in decreasing the waste thus

on-site composting and organic waste reduction techniques are also used.
Minimizing the toxic levels in the waste in the municipal waste sector.
Decreasing the weight of the waste material which is entering the solid waste stream.

Tools of Waste Reduction

Waste reduction can be achieved by using the lean manufacturing tools and techniques. Lean
design and manufacturing help in minimizing the waste. Lean Manufacturing recognizes 7 types
of wastages and the tools of lean manufacturing are shown below. Table for lean manufacturing
tools and their remarks:

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Figure 2 (Mahapatra & Mohanty, 2006).

Cellular manufacturing: This is the first tool in the lean manufacturing. Cellular manufacturing
involved in the alignment of the manufacturing the machinery and equipments in a group which
supports the components and material in the production process without any kind of delay.
Cellular manufacturing helps the companies in minimizing the time required for the
manufacturing of the product and in attaining the necessities of the customers (Lean
Manufacturing).

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Just-in-Time: JIT is the second tool of lean manufacturing. The requirement of JIT in the
company is to supply the required products effectively when they are in need or required and not
before.
Kaizen: Kaizen is the third tool of lean manufacturing. The main function of Kaizen is to
process the continuous improvement (Mahapatra & Mohanty, 2006).
Kanban: Kanban is the fourth tool of lean manufacturing. This was an information tool which
recognizes the products during the manufacturing process and precisely when they are required
(Lean Manufacturing).
Poka yoke: This is the last tool of lean manufacturing. The word poke yoke denotes to the error
proofing in manufacturing process which stops the defective products during the design phase
(Lean Manufacturing).
The major sources of waste in the Production Process:
Over Production
Waiting
Conveyance
Processing
Inventory
Unnecessary Motion
Processing Failures

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Space
Over Production
Overproduction waste means the act of making or doing something for which there is no
consumer. This was a practice in advance for adapting the lean manufacturing standards and is
known as stockpiling.
Waiting
Waiting waste significances looking for tools, or from waiting for materials, data, or machine
setups (During the production process if the employees are idle because of the waiting for the
required parts and the machinery, the effectiveness of the production process is negotiated).
Conveyance
Conveyance waste includes the superfluous moving of parts or data.
Processing
Processing waste appears when the heavy or huge amount of work was carried out at the time of
product manufacturing than is needed by the customers conditions, or when the information or
data had entered into many multiple areas.
Inventory
Inventory waste arises when resources are utilized to stock products that have not been
demanded by a client. (The act of building up stock of parts or products is otherwise called
"stockpiling.")

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Unnecessary Motion
Waste from unnecessary motion means spending time on the extra activities, such as walking for
the parts which are required for the assembly. Unnecessary motion is alike to conveyance waste,
but it applies to the employees while conveyance waste relates to extra movements of parts and
information.
Processing Failures
Processing failure waste indicates to the spent on transforming defective products or
components.
Space
Space is wasted where more land was used than required. Extra space indicates more utilities and
above needed to deal with the space (Lean Manufacturing).
10 Keys to a Successful Waste Reduction
1. Top Management Support
2. Employee Interest and Involvement
3. Enthusiastic Leader
4. Set and Define Clear Goals
5. Determine What Will Be Recycled
6. Focus on Waste Reduction
7. Design the Collection and Storage System
8. Bid Out Recycling and Waste Collection Contracts
9. Education Program
10. Promote Program Internally and Externally ( Washtenaw, 2015).
Reasons behind in implementing the waste reduction in an organization

By implementing the waste reduction in an organization it saves a lot of money on the

suppliers.

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It also helps in conserving the energy resources for the future use.
Waste reduction minimizes the present waste disposal and evade on increased waste

disposal cost in the coming future.

It satisfies the customer needs and try to reach their expectations in the manufacturing the

products with more durability.

It maintains the environment in the balanced manner without disposing the unnecessary

materials.
In the manufacturing plant it helps to minimize the time and improves the quality of the

product with high quality.

Waste reduction encourages the workers to participate in the environmental projects so

that they give morale to the fellow members.

It minimizes the risk in the future (Rhonda).

Selecting team members and identifying their roles and financial compensation:
The team selection was done based on their skills which can assist the company in completing
the project task successfully. That includes business experts, outside monitors, technical experts
and outside supplier experts. Team members plays a vital role in completing the task of the
project in the given time span successfully. This can be done by informing the regular outcomes
of the project to the project manager because if there were any issues that affect the outcome of
the project. The team members should come up with their new ideas in their field of work which
sets the responsibilities to the team to manage their task regularly (Project teamwork).
Team Leader
The role of a team leader is to collect the resources available to complete the required task. Main
motto of a team leader is to set the goals in order to reduce the waste, complete the work in time,
improving quality etc. Setting a target to reduce the waste involves choosing the equipment

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required, staff involvement and training. The other key function is controlling and monitoring the
resources to achieve the goal (Business case studies).
Manufacturing engineer
The key role of a manufacturing engineer is to increase the efficiency and to improve the
performance of a company. As a manufacturing engineer reducing the waste which wont add
any value to the company, increasing the efficiency of production and reducing the production
issues (Target Jobs).
Lean is providing an opportunity to many organizations which helps to reduce the waiting time,
improve in product quality, reduction in operating costs and improvement in services to the
business sector.
Important things we need to consider mainly for improving the efficiency of the production
process and in reduction waste includes:
1.

Regularly checking the equipments.

2.

Reducing the excessive stoppages in production line

3.

Upgrading the old equipment.

4.

Minimizing the leaks.

5.

Using the sealed systems.

Prevention is better than cure, of course. Constant monitoring, of production processes and
preventive maintenance can ensure waste is avoided before it occurs (nibusiness).

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Production planner
The main characteristics of a production planner are to plan the activities and making scheduling
to ensure the selected material and its capabilities meet the needs of customers. Production
planner responsibilities are to identify and report opportunities to reduce the waste, time,
operating causes.
Lean manufacturing consultant
Lean manufacturing consultant creates innovative strategies and they develop unique ideas or
strategies for changing operations in order to achieve the production goals by reducing the waste
by utilizing the resources in right way.
Maintenance Engineer
The main role of maintenance engineer is to identify and analyze the issues in equipments and
to perform the periodic maintenance for the inspection of the machinery.
Responsibilities of team members
The responsibilities of team members will include:

Gaining knowledge on the project scope and one should know the purpose of the project.
They help in identifying the issues and risks involved in the project.
Team members in the team should work together as a team and with the good

communication.
They help in manufacturing the products according to the specifications required by the

customer.
They should maintain a balance between the project and the non- project work.
They contribute towards the positive motivation.

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They need to report the progress of the project every day to the project manager (Project
teamwork).

Determining Project deadlines:

The most important and essential step in the project is generating the dead line which makes us
in finishing each and every aspect in the project. Identifying, the steps that are involved in the
project and the sequence steps that occurring will assist the company in completing the task of
the project successfully in the time period.
Here are 20 steps for implementing lean manufacturing project:
Waste reduction can be achieved by implementing the tools and techniques of lean. So that it can
produce the more quality products and long lasting goods, improve the quality of the product,
save time and money. Here are the steps which required in implementing the lean techniques in
the manufacturing plant.
1. Build a team - selecting team members who were capability in the area of lean manufacturing
and related business knowledge.
2. Introducing communication and feedback guide for each individual.
3. Gather every individual and explain the project plan.
4. Training all workers on the eight wastes, Kaizen, lean overview, standard operations.
5. Equipment analysis.
6. 5-S - Which is the creation of lean.

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7. TPM Commencing Total Productive Maintenance.

8. VSM - Value Stream mapping which describes the waste beyond complete process.
9. Identifying wastes
10. Process mapping A complete guide of each operation.
11. Takt time Regulate need to provide on all operations
12. Overall equipment adequacy and six losses Control the losses on all operations
13. Line equalization Use, if essential, with takt time
14. SMED Drive setup times down to decrease process duration.
15. Pull/Continuous Flow Analysis/one-piece stream.
16. Examine quality at the source requisition Poor quality completed at the source.
17. Executing error - proofing ideas.
18. Cellular manufacturing Scrutinizing facility and each operation.
19. Initiating quality operations Instantaneously with SMED, flow, line balance, designs.
20. Kaizen Improving operations constantly, providing right of way to limits within the
association (Wright).
Creating a Work Breakdown Structure and defining work for all team members:

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Project milestones and deliverables:

Milestone # 1: Project start-up

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Objective: To start the project implementation. Recruit a strategic idea for the organization.
Trainee the teams and develop them to identify the goals. Collect the information which is
needed for Kanban and line design.
Milestone # 2: Final check
Objective: Complete the collecting of required information. Achieve agreement and guiding
close down for demands and products. Finish Sequence of Events (SOE) exercises operation
times and throughout variables.
Milestone # 3: Factory design
Objective: Draw the copy of the waste management design which is utilized in the resources
of the Process Flow Diagram. Develop a lean line start up policy. Recognize the need to
manage training.
Milestone # 4: Line start-up:
Objective: Begin line up. Approve the tasks of workshop and examine for ergonomic design.
Relate the two-bin material kanban system. All the training should be completed. Create reduced
work-in-process assumption bleed-down scheme. Make sure that the continuous process
improvement system has been initiated.
Milestone # 5: Internalize
Objective: Analyze line execution and the survey acceptance to the methodologies of lean.
Recognize dissimilarities and begin strategies. Audit the responsibilities of an organization and
change procedures to enable lean operation and ensure that all kanban framework has been set
up.

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Determine and list the Critical Path:

Critical path is defined as the planning of project network exercises which indicates the longest
total duration. It helps in deciding the shortest time possible to complete the project. To complete
the project successfully one should manage the tasks and the critical path. The tasks that are
comprised in the project will be allocated estimation, duration, and the time period. The networks
between the tasks are called as dependencies are habituated. The longest duration of the path in
the project between the dependent tasks and by computing the durations instantaneously critical
path is calculated.

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Conclusion:
As a conclusion many organizations around the globe was implementing the waste management
to enhance the product quality and durability. This can be achieved by using the lean
manufacturing tools and techniques such as Kanban, 5s, poka yoke, JIT and cellular
manufacturing helps in eliminating the waste. A successful implementation waste management
in an organization with proper scheduling can help any organization in preserving a safe work
environment, decreasing the turnarounds, improve the quality of product and minimize the cost.
Waste reduction assists the company in reducing the cost of the raw materials, machinery and the
equipment that is used for the production process. Streamlining procedures to minimize the
waste can achieve by the efficiency and the productivity also. Additionally, waste reduction
helps in maintain the environment in a balanced manner and also enhance the clients loyalty. So,
many companies adapt waste reduction as an important element of their long term business.

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http://www.conserve-energy-future.com/advantages-and-disadvantages-of-recycling.php

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http://scp.eionet.europa.eu/themes/waste
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http://www.ksre.ksu.edu/bookstore/pubs/6manag.pdf
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