How Automation and Analysis can Reduce Waste

One of the key indicators of efficiency for any business is waste, and it is something that is often overlooked or ignored from a front-line perspective. Management teams have focused on waste for years, implementing strategies of finding a ‘taker’ for it or reducing it outright, with the latter being preferred. Toyota is a great example of a company that has its eyes open to waste, and not just from production.

Waste comes in many forms outside of our tangible definition for physical material, and occurs from a supplier and producer perspective. Overproducing is a form of waste, as are delays and transportation inefficiencies. Unneeded movement is even waste - the just in time production and inventory management system employed by Toyota is a great example of a strategy to reduce waste.

Automation and Waste Reduction

Automation not only decreases direct labour requirements, it can reduce variability and allow for a logical system of control or influence over value-add production. While indirect labour is now required to maintain automation routines, programming or hardware — such as an analyzer being used for freeness control of pulp production. In most cases the product used by the analyzer or automated solution is returned back to the process, helping to maintain an efficient production system.

Production System Considerations and Supply Chain Integration

Production systems and supply chains are highly integrated. The quality of the inputs for production impact waste and efficiency as does the quality of the output from an outbound supply chain perspective. Is transportation, rail cars or transport trucks, inspected for empty space? Is unnecessary packaging being applied? Sometimes it is as simple as stepping back and acquiring a new perspective of the existing system. Too simple to do and not ask.

There is an informative article on this subject written by Sutherland and Bennett (2008). It was published here, and is a light, great read.