Effective Ways To Reduce Manufacturing Waste

Manufacturing waste is inevitable in any manufacturing plant. However, the amount of waste you produce can negatively affect your production cost. The more waste you create, the more your production cost increases. Leftover remnants of unneeded raw materials are an example of manufacturing waste. But other components like labor, time, and capital can also be wasted due to product defects, overproduction, inventory issues, and so on. If your manufacturing business experiences too much waste in its production process, here are some effective ways you can reduce such waste. 

1. Use the right manufacturing tools

The right tools can significantly improve the production process, while incorrect tools will waste time and lead to damage. Tools may also be ineffective and cause waste if employees are not well trained on how to use them. No matter the type of tools you may need, it is important to invest in the right ones to ensure maximum output and reduce wastage. For example, if your manufacturing process requires cutting and drilling aluminum materials, you want to invest in tools like an end mill for aluminum. 

2. Create efficient inventory management

Another way to reduce manufacturing waste is to create an efficient inventory management system. The aim is to reduce how many excess raw materials you have in stock. And the best way to do this is to limit your purchases of raw materials to only the amount you need for any production process. Understandably, there is always the urge to order more materials, especially in the face of current global supply chain issues. But if you’re looking to avoid or minimize manufacturing waste, you should only order the needed quantity of raw materials for a specific production period. 

3. Extend the lifespan of waste materials

You can reduce manufacturing waste by finding ways to extend the lifespan of manufacturing leftovers by creating other uses for them within the manufacturing process. Also known as closed loop production, this methodology involves using recycled materials in your production process instead of virgin raw materials. Other closed loop manufacturing strategies work to extend the lifespan of waste materials by taking advantage of system innovations to reintroduce the wasted materials into the manufacturing lifecycle. 

A closed loop system can also help extend the life of manufacturing chemicals by maximizing their use. That means businesses can significantly reduce the number of new chemicals they purchase and minimize the amount of contamination as a result. 

4. Identify the key waste areas

Any part of your manufacturing process that offers no value to your customers or your bottom line is waste. That means manufacturing waste can exist in almost any department in your business, including your labor and time. Identifying any area of your business that offers no customer value but attracts costs is important. For example, are there workers occupying positions that bring no benefits to the manufacturing or production process? Do you experience too many delays in the production process? Do you produce more goods or items than your customers need?