CONTROL WASTAGE

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



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



Gasket

Drawing



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.



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.



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.



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.



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.



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.



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.



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.



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.



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.



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.



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



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.



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.



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.



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.



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.



Increase in wastage adds to company¶s cost hence less

profit, less productivity, wastage of time and also

wastage of resources.



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



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



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



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



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

CONTROL WASTAGE

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