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3M3M is a Japanese concept derived for shop floorimprovement

It contains 3 elimination activities

Since it starts with letter M it is called as 3M

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Waste in Value System

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MUDA(WASTE)MUDA stands for eliminating Non Value Addedactivities

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7 TYPES of MUDA MUDA of Production (Over Production)

MUDA of Waiting

MUDA of Conveyance (Transport) MUDA of Over or Incorrect Processing

MUDA of Stock (Over Stock)

MUDA of Workmen Movement

MUDA of Defects

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MUDA of PRODUCTIONProduction more than requirement Production earlier than requirement

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MUDA of WAITINGMachine breakdown

Die breakage or die problem

Pallet shortage Die set up time (SMED)

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MUDA of CONVEYANCE Panel changing from WIP pallets to DespatchPallets

Operation pending production

Unnecessary movement of fork lifts

Changing panels

from WIP palletto CC pallet

Operation

pendingproduction

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MUDA of CONVEYANCE

Lot size 4000 Nos

Qty/trip 500 Nos

No of trips 8

Lot size 4000 Nos

Qty/trip 2000 Nos

No of trips 2

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MUDA of Over or Incorrect

ProcessingPanels undergoes additional process to satisfy thecustomer requirement

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MUDA of STOCKOil spraying to avoid panel rust Rust cleaning due to panel oil stain

Pallet shortage for less stock items

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MUDA of WORKMEN

MOVEMENTNon value added operator movement

No panel diverterPanel diverter

available

Difficult to pick

the panel

Easy to pick the

panel

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MUDA of DefectsProduction of defective parts

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MURI (Over Burden)MURI stands for any activity that exceeds actual capacityof Equipment or Operators

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MuriOverburdening people results in Safety and Qualityproblems

Overburdening Equipment causes Break Downs andDefects.

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Use of 2.5 T fork lift instead of 5 T fork lift

Lifting two dies at time with EOT crane

Press over load due to double panel loading in thedie

Double sheet feeding in shearing machine

CORRECTWRONG

2.762 Ton with

2.5T forklift

2.762 Ton with

5T forklift

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Strain while

moving the pallet

No Strain while

moving the pallet

Two dies lifted at

time

One die lifted at

time

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MURA (Unevenness)MURA stands for any activity that containsinconsistency or ineffective utilization

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Unevenness results from an irregular productionschedule or fluctuating production volumes due tointernal problems, like downtime or missing parts ordefects.

Muda will be a result of Mura

MURA (Unevenness)

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MURA (Unevenness) Unequal allocation of work to operators The work load for the last operator is not balancedwith other two operators

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Heijunka (Level out the

Workload)Achieving heijunka is fundamental to eliminatingMura, which is fundamental to eliminating Muri andMuda.

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Heijunka (Level out the

Workload)Heijunka is the leveling of production by both volumeand product mix

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Heijunka (Level out the

Workload)It does not build products according to the actual flowof customer orders, which can swing up and downwildly.

It takes the total volume of orders in a period and levelsthem out so the same amount and mix are being madeeach day.

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Traditional (Unleveled)

Mixed Model Production

(Leveled)

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4 Benefits of Leveling the

ScheduleFlexibility to make what the customer wants when theywant it

Reduced risk of unsold goods

Balanced use of labor and machines

Smoothed demand on upstream processes and theplants suppliers

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To sustain Cost Reduction, eliminate these 3M inshop floor.