3 m

1

Object of Enterprise

• To Increase Profit– Growth by Top & Bottom Line– Living Standard Improves

Presented by: PAWAN SEHRAWAT

2

INCREASE PROFIT

× Selling Price = Cost + Profito Profit = Selling Price – Cost

Selling Price is Decided by Market

Leads to

Actual Movement of Reducing Cost

Presented by: PAWAN SEHRAWAT

3

Reduce Cost

Decided by manufacturing method

Material Cost

EnergyCost

Processing Cost

Others

Cost Price

Processing Useful Job from customer point of viewConveyance

Inspection

Stagnation

Waste

Worthless Job does not increase value to the process

Remove Waste

Actual movement for Reducing Cost

Presented by: PAWAN SEHRAWAT

4

Concept of 3M

Presented by: PAWAN SEHRAWAT

5

3 MU’s

MURI – STRAIN

MURA – INCONSISTENCY / IMBALANCE

MUDA – WASTE

Muda

MuraMuri

Presented by: PAWAN SEHRAWAT

6

Elimination of MUDA (Waste)

What is MUDA

Operation = Work + MUDA

Work = Increases value of production

MUDA = Increases cost of production

Kaizen (Improvement)

Total amount of labor No Change

= Work MUDAMUDA

Working

Work

Work + MUDATo 100%Labor Density Effectiveness =

Presented by: PAWAN SEHRAWAT

7

Type of Mudas

Presented by: PAWAN SEHRAWAT

8

Types of MUDA (Waste)

MUDA of OverproductionMUDA of StockMUDA of Conveyance (Transport)MUDA of WaitingMUDA of Operation ItselfMUDA of Movement of WorkerMUDA of Production of Inferior goods

MUDA Monster

Profit

Presented by: PAWAN SEHRAWAT

9

Over Production is the Worst MUDAIncrease Raw Material Purchasing( MUDA of Stock)

Increase Workers

Add Machines

Loose Money

NecessaryQ’ TY

Over Production

Meaningless Increase of Efficiency10 Workers : 100 Products

10 workers : 120 Products

Necessary Q TY : 100

Over Production

Store House Conveying Equipment Bin

Additional ware House

LooseMoney Conveyance

Interest Rate

Moving Material which is not Required

Presented by: PAWAN SEHRAWAT

10

Sample of MUDAMUDA of Overproduction

Before installing pipe on productmake a lot of pipes on preparationtable

Only one is necessary for product

Within one cycle to make only necessary quantity

Presented by: PAWAN SEHRAWAT

11

Reduction of walking distance MUDA of Movement

Working order is changed 1 2 3 4 5 61 4 6 2 5 3

Presented by: PAWAN SEHRAWAT

12

MUDA of Stock

Will add cost of :-

– Tools

– Inventory

– Poor Life

– Scrap due to method change (Obsolete)

– Storage and upkeep

– Searching

Presented by: PAWAN SEHRAWAT

13

MUDA of Transportation

Loading

Transfer

This worker is changing parts to new pallet.

Presented by: PAWAN SEHRAWAT

14

MUDA of Transportation

Install

Carry

CarryTo Temporary

Store

FromWare House

To PlantNext

Nextto the

Machine

To the Opera

Aren’t you doing this kind of useless transport?

Presented by: PAWAN SEHRAWAT

15

MUDA of Waiting

While filling water in A C,do other job

Bad case Waiting until a can is filled

Presented by: PAWAN SEHRAWAT

16

MUDA of Waiting (Case 2)

Operator has to walk long distance

(2 ‘S’)

By rearranging parts save moving distance with in arm -reach

Presented by: PAWAN SEHRAWAT

17

MUDA of Operation

Installation of bolt and screw (Two types of head)

Worker uses two kind of air toolsFor Screw

For Bolt

Improvement of air tool

Combining / modifying to use both without changing the tool head

Presented by: PAWAN SEHRAWAT

18

MUDA of Movement

Shortage of a Tool bit/Socket Small

bagfor small part and tool bits

Worker goes to take a tool from the rack repeatedly

Presented by: PAWAN SEHRAWAT

19

Adoption of part boxMUDA of Movement of Worker

Workers go to take parts repeatedly

Part Box

Presented by: PAWAN SEHRAWAT

20

MUDA of Production of Inferior Goods

Due to incomplete installation of tool and Jig

MUDA (Inferior goods) of manufacturing

1. Effort for job is high

2. Non-conforming to specification

3. Worn socket

4. Incomplete tool

5. Low productivity

Do operation over again

Use Jig

Presented by: PAWAN SEHRAWAT