LEAN is a principle that all manufacturing companies should master. It helps companies become more profitable by reducing non-value added activities.

In this third of a 8-part LEAN series, we will discuss how manufacturing companies can reduce Waste in Motion in their operations.

What Is Waste In Motion?

Waste in Motion refers to the unnecessary movements performed by the operators or by the machines to complete a product.

These excess motions consume time, energy and resources increases costs without adding value to the product.

Why Is Motion A Form Of Waste?

If it takes too much motion to complete the work, cycle time will be longer. The longer the cycle time, the more costly it will be to build the product.

More motions also means more fatigue for the operator. This will reduce operator efficiency, quality and output.

More motions also means higher risks of repetitive or strain injury. This could translate to operator downtime, higher health insurance premium and negative workplace morale.

Machines moving too much will result in excessive wear, repair and downtime.

What Are The Forms Of Waste In Motion?

The waste could appear in several forms.

Operator having to get up to reach for parts or tools during assembly.

Operator having to change tools multiple times for the same assembly.

Assembly robots making unnecessary movements or tool changes during assembly.

How To Reduce Waste In Motion?

For manual assembly, improving ergonomics will be one of the key areas.

Frequently used materials or tools should be within easy reach of the operators.

Use powered tools when possible to reduce operator stress and improve repeatability.

Optimize the product design to reduce the need for tool changes during assembly.

When possible, tools should be light in weight. Employ balancers and arms to reduce operator efforts.

For robotic or automated assembly,

Optimize machine movement to reduce the amount of travel.

Make use of more versatile tool changer/holder if possible to reduce the amount of tool changes.

Conclusion

Being LEAN is something that all manufacturing companies must master. It could directly impact the company’s profitability. The cost for waste in motion could be huge, especially when operators sustain repetitive or strain injuries and thus incurring additional medical or insurance costs. Even robots with too much waste in motion will result in higher operating cost in parts, repair and maintenance. Optimize the motions for each operations and it will result in the lower cost of assembly and operations.

How have you reduced Waste In Motion in your experience? Let us know by leaving a comment below.

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