Overproduction means “ Producing the products in excess quantity which are not required for next operation or Customer.”
Over Production Waste occurs when we manufacture, assemble, or build more than what is needed. We make some thin just in case instead of Just in time (JIT). In accurate scheduling, long lead times, long changeovers and not being close enough to our customers to understand there changing needs leads us to longer production runs. We worry that our customer might need more while we have to suffer with the associated cost of unsold goods or services.
Look for processes producing more than is being “pulled” by the customer and requiring storage between processes.
Reduce by improving change over and set up times and balancing production lines.
Overproduction increases Money spend for:
- Energy
- Record keeping
- Documentation
- Tooling Cost
- Manpower cost
- Overheads
- Space for Storage
- Inventory cost( Reduction in Inventory Turns ) This is hidden money.
Why ? Overproduction
1. No Confidence in process
2. No confidence on set-up Quality
3. No confidence on equipment
4. No confidence on people ( Operator .. Availability )
5. Meaningless increasing efficiency
6. Available = Make Use …. Concept followed
How to avoid Overproduction
1 .Do not produce more than next process demand
2. Build confidence in process, set-up
3. Improve m/c condition
4. Improve attendance / Multi-skilling
Indirect ways of reducing over-production
1. Reduce Finish Goods area
2. Reduce space between two operations
3. Implement 100 % 2 S
Management’s role :-
• Communicate to all for following the concept... Produce when next process demands.
• Decide WIP norms and FG Norms.
Overproduction results in
a) Increasing rejection , scrap
b] Reducing CASH-FLOW
c] More searching and sorting
d] BAD 5 S
e] Moving Company towards opposite direction of world Class
Overproduction HIDES
A] Waste of WAITING
B] Waste of MOVEMENT
C] Waste of TRANSPIRATION
D] Waste of PROCESSING or OPERATION
Useful Links to Read:
01. history-of-total-productive-maintenance
02. why-implement-total-productive
03. what-is-tpm
04. 12-steps-for-tpm-implementation
05. typical-tpm-organizational-chart
06. effectiveness-of-tpm
07. 5-principles-in-tpm-development
08. purpose-and-main-activities-of-kk
09. purpose-and-activities-of-jh-pillar
10. purpose-activity-of-pm-pillar
11. purpose-activities-of-qm-pillar
12. purpose-and-activity-of-dm-pillar
13. purpose-and-activity-of-otpm-pillar
14. purpose-and-activity-of-e-pillar
15. purpose-and-activity-of-she-pillar
16. company-wide-tpm
17. jishu-hozen-information
18. ishu-hozen-equipment-deterioration
19. role-of-production-maintenance-in-jh
20. jishu-hozen-step-1
21. 1s-2s-implementation
22. jh-step-01-abnormalities
23. exposing-seven-types-of-abnormality
24. 2-unfulfilled-basic-condition
25. 3inaccessible-places
26. 4-contamination-sources
27. 5-quality-defect-sources
28. 6-unnecessary-non-urgent-items
29. 7-unsafe-places
30. jishu-hozen-step2
31. jishu-hozen-step-3
32. one-point-lesson-opl
33. visual-control-visual-management
34. 35. what-is-smed
36. why-energy-conservation
37. mobile-phone-handling-important-tips
38. kaizen-way-of-life
39. what-is-kaizen
40. techniques-used-in-kaizen
41. tmv-mba-project-guideline
42. gdmm-project-guidelines
43. importance-of-energy-conservation
44. global-warming-25-tips
45. latest-abcd-from-nursery-school
46. world-environment-day-5th-june
47. be-proud-to-be-engineer-happy
47. lean-tools-hidden-waste
