BMFP4413 MANUFACTURING MANAGEMENT WASTE: UNNECESSARY MOTION, UNNECESSARY PROCESSING , WAITING. SOLUTIONS: 5S, Standard Operating Procedures (SOP), Yamazumi Chart or Line Balancing Chart, Kaizen

1. BMFP4413 MANUFACTURING MANAGEMENT
Types of Wastes in
Manufacturing
Members;
1. Sisubalan a/l Selvan B051410128
2. Badrul Ridwan bin Kamarol Hisham B051410180
3. Tan Boon Yee B051410099
4. Goh Yong Shen B051410131
5. Mohd Farid bin Che Awang B051410202
Marked by:
PM Dr Mohd Rizal bin Salleh

2. A) WASTE: UNNECESSARY MOTION
Figure 1: a) Searching for tool, b) Messy benchtop
Problem 1 : The workplace layout is not planned well as the worker need to walk
to another machine to get the tool he need. It is considered as an
unnecessary motion and it could further lower the work efficiency.
Besides, the workers will also feel tired and stress to walk around just
to get the tool he need.
Problem 2 : The benchtop of the tools is disorganized and messy. It made the
worker difficult to find the tool he needs and waste a lot of time. This
could also reduce the work efficiency.
SOLUTION:
Figure 2: Organised toolboards

3.  The problems can be solved by implement an organised tool board. The tool should be placed
in order on a tool board as well as labelled with their name respectively.
 It could ease the worker to obtain the tool he needs and don’t have to waste time to walk
around or find the tool. Furthermore, it can increase the work efficiency since the
unnecessary motion is eliminated and worker will be feeling tired easily.
B) WASTE: UNNECESSARY PROCESSING
Figure 3: Over processing by worker
Problems:
1. Operators try to do the best job possible and will not always be aware of what truly adds
value to the product or even the end use. In this case consume time and will expend time
polishing and finishing components that do not require it.
2. Another issue is the one of non-standardized working practices unless operator has
standardized working then will have differences in methods between different shifts and
different people.
Solutions:
1. Standard Operating Procedures (SOP)
 All staff shall receive job-specific training on equipment operations and
maintenance as a part of orientation. Staff shall be fully trained in all steps of
proper equipment use, including associated hazards and precautions.

4. Figure 4: SOP sheet
2. SOP Board / Checklist
 The problems can be solved by implement an SOP board. The SOP board should be
placed in convenient place near the workplace and easy to be referred to at any time.
 To perform a job properly, performed consistently and ensure that process continue
uninterrupted and are complete on a prescribed schedule.
C) WASTE: WAITING
Figure 5: a) Workers not trained well, b) Waiting for colleague to help

5. Problem 1 : The worker is not properly trained which leads to waiting as the
worker looks for the procedures or the standard for the process. This
may also leads to other wastes like unnecessary motions and defects.
The worker maybe a new worker that may didn’t expose to proper
training or the training may difficult for them to understand. Hence,
this consumes time and maybe stops the production for a while that
affect the production rates. This is also may leads to some health
problems or accidents due to the ignorance of the clothing ethics by
the workers during the work (Taking off the glove).
Problem 2 : The worker seeking for helps and waits for his colleagues to finish
their products parts during working to help him understanding his part
in the manufacturing line. His colleagues may don’t know how to
handle the machine since it is not their expertise.
SOLUTIONS:
1) Standard Operating Procedures (SOP)
 With use of SOP while training, it may provide the workers to know and follow the
standards as provided on the SOP sheets. Meanwhile, for foreign workers who can’t
understand and read in the national language or English, the SOP will be provided in the
language of the foreign workers to enable them to easily understand it.
 Assign the new workers with old workers to supervise and train the workers following
the SOP standards. The supervisor may be in the same nationality with the new worker
for easy understanding. This system may also know as the buddy system.
 The SOP will be attached to every parts of the manufacturing machine in the production
line for the workers to easily access it and refers during working. Due to the presence of
the SOP, it may also reduce others wastes like over processing of the product that doesn’t
not add value and defects.

6. 2) Yamazumi Chart or Line Balancing Chart
Figure 6: Yamazumi Chart for welding processes
 It is also known as takt time bar chart at which the process steps can be rearranged or
deleted to optimize and balance the target process. It also uses in to aid the training
purposes. The Yamazumi board provides a mechanism to rebalance a process when
Takt changes quickly. It allows a visual indication of which operations are overloaded
(beyond takt) and underutilized. Hence as for this process, the time wasted and taken
by the worker can be reduced once it is identified through this method.
 By rearranging the tasks, workers from tasks may also able to intercept with the new
worker and help the worker. It is may also aid in the formation of new cell layout
based on the 5S.
3) Kaizen
 It is a continuous improvement involving all employees of a company work
together proactively to achieve incremental improvements to the manufacturing
process.
 We also may able to teach the workers about the safety and the function of the
gloves (workers taking the gloves off when working). Meanwhile, the workers
can share their problems like the gloves are too fit to their and may come up with
other protective clothing.
 The workers that having difficulty in one station in production line may also will
able to transfer to other station that they can operate. (Especially the special needs
workers).