Post on 10-Apr-2018
8/8/2019 CONTROL WASTAGE
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Fasteners (nut +bolt etc)
Welding rods
Lock plates Keys
Kerosene
Pressurized air
Stoppers
Clothes
Cotton wastages
Grinding screen
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Asbestos hand gloves
Hacksaw blade
Leather hand gloves
Molly coat
Silastic
Grinding wheel (Mop+Stone) Grinding belt (emery)
Grease
Emery paste
Oil
Shims
Coupling bolts
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Gasket
Drawing
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1:Wastage of electricity
Switch off head bulbs of shop
floor, tube lights of offices
when work is possible in
daylight. Switch of fans, Air
conditioners.
Switch of the Computers etc.
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2:Wastage of drawings
Drawings should be placed in the
respected racks after usage so that
for future it will be easy to found
out.
Only carry those drawings from
racks whose processing is going
on.
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3:Wastage of fasteners
Storage of fasteners should be
proper as per the dimensions and in
particular racks so that it will be
easy to identify.
Storage should be away from dirt,
dust, water.
Take required quantity of fasteners
at the work place, if balanced after
work completing keep the
remaining in the respective rack. Temporary fasteners used for
wheel mounting and drive
mounting should be kept in proper
rack.
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4:Wastage of Oil, Kerosene
Fuel drums should be lifted
carefully and placed properly so
that no damage should occur in
drum which may result inleakage.
Closed the drum¶s openings so
that no dust settles in it.
Place it away from heat.
Bring back th oil drums lying inFirst shed and New shed.
It should not be used in excess.
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5:Wastage of Welding rods
Welding rods should be utilized
till its full length.
During welding the contact
point of metal and welding rodshould be at proper distance this
result in less smoke, proper
metal deposition.
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6:Wastage of Pressurized Air
The Hand grinders, Bolt tightners should be kept off after usage.
Leakage of pipe should be informed to the maintenance dept.
Compressor requires very high power for compression of air hence,main valve should be closed after use.
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7:Wastage on Keys
Machining (grinding) should be done properly as per tolerance
required .
Keys should be placed in proper column so it can be easy found.
Donot use machined keys for supports.
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9:Wastage of Cottons, Clothes
Cotton and cloth should not be
thrown away after used one¶s, it
should be reused if it is in a
good condition to clean thesurface etc.
It should be store at a height so
that it should not get in contact
with water, oil, grease etc.
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10: Wastage of Grinding Belt and
Wheel Grinding wheel and belt should
be used till it is in a good
condition of removing
unwanted particles. Hand grinder like buff grinder
and disc grinder should be
placed in proper place.
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11:Wastage of Grease
Grease should be used as per the requirement and not in excess.
It should be kept away from water and dusty area by applying seal (
cover ) on it.
Use their application only in those places where it is required.
Use plastic buckets for carrying grease and keep it back after
application in stores.
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12: Wastage of Stoppers, Lock
Plates, Coupling Bolt. Every particular items should
be used at its respective
assembly.
It should be placed in areawhere it can be easily found.
Donot use lock plate for
packing purposes.
Dismantled coupling bolt
should be kept in coupling boltrack as per size.
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13: Wastage of Leather and
Asbestos hand gloves. Hand gloves should be kept
away from water and should be
used till it is in good condition
of usage. As per gloves specification it
should be use in their respected
area from safety point of view.
Used hand gloves should b
return back to the stores
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14:Wastage of Hack saw blade Blade should be used till it is in good condition for operation.
During operation coolant should be applied for increasing blades life.
Only use blade on those materials which can be cut ( i.e not on
hardened jobs.)
Fixing of the blade has to be done as per the OGT given.
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15:Wastage of shims
Cut out shim should not be
thrown because it can be
reused, recycle.
Use proper item nos of shimsaccording to th machined pad.
Bring back excess shims and
keep it in proer rack.
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16:Wastage of Gasket
Gasket should be kept away
from water, heat.
Cut outs of gasket can be used
for other smaller jobs.
Cut the gasket at a proper
location to achieve full
utilization of sheet.
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17: Wastage of Grinding,welding
screen It should be handled carefully
to avoid breakage.
It should be kept at a sufficient
distance during operation toincrease life of screen and also
workers safety.
Welding screen, grinding screen
and goggle should be kept back
at proper location.
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18:Wastage of time
Avoid rework and repair if
possible so things should be
done right from the beginning.
Shift Starting\Ending time andTea\Lunch break to be adhered
strickly.
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Increase in wastage adds to company¶s cost hence less
profit, less productivity, wastage of time and also
wastage of resources.
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Losses occuring per dayMaterials Cost\unit
Lock plate
Kerosene
Oil
Molly coat
Hack saw blade
Polish paper
Plastic tube
RS 32
RS\LT 40
RS\LT 175
RS\LT 1536
RS 164
RS\PIECE 28
RS\MT 24
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Grinding wheel (63x16x10)
Buffing wheel (60x25x6)
Hand gloves asbestos 16´
Hand gloves leather
Rubber sheet
Loctite
Face shield
Grease
Flat belt (50mm x 970mm)Stopper
Coupling bolt
RS\PIECE 50
RS\PIECE 72
RS\PIECE 120
RS\PIECE 52
RS\KG 44
RS\KG 935
RS\PIECE 93
RS\KG 365
RS\PIECE 87
RS 26,36,59,57
RS 45,54,90
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Fasteners (nut + bolt)
PL. Washer
SP. Washer
Shims
Machined pads
GasketWelding rods
Keys
Cotton and clothesSilastis
Grinding screen
Emery paste
RS\KG 75
RS\KG 70
RS/KG 4.55, 2.50, 1.77
RS/KG 35,121,55,60
RS\KG 275,425,525
RS\KG 175
RS\PIECE 3,4,5
RS 180,340,710,120
RS\KG96
RS\PIECE 171
RS\PIECE 140
RS\KG 52
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If we consider that per piece of each item is wasted per day then
the total loss to the ³MBD ASSEMBLY´ will be around
RS ³6110´
.If we consider loss for a month then it will be around
30 x 6110 = RS 1,83,300
If we consider loss for one year then the loss will be around
365 x 6110 = RS 22,30,150
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So we all being part of the company its our
duty to look after our future as well ascompany¶s future .
You Shine
Department Shines
Company¶s Profit Increases