15 Points to reduce 'Motion' Waste from your shopfloor

Lean Manufacturing focuses on Waste Elimination. Motion Waste is one of the seven wastes that can be easily reduced. In this article, I have listed  15 points to remove the Motion Wastes (Wastes from Human Actions) from the workplace. This would be a great tool for industrial engineers who are looking to reduce Motion Wastes in their shopfloor.

1. Using Both hands to start / Stop the machines – when a manual activity requires the use of both hands, they should move in unison. Keep Arm Movements simultaneous and symmetrical
2. Reduce / Eliminate Operator walking during work – how to create a workplace where the operator does not need to move / walk during the operation. Everything he/she needs should be in the workplace 
3. Minimize Leg and Torso movements – keep the parts nearer to the usage. Operators should not turn around for picking / placing. Operators should only move their Arms, wrists and fingers. Follow Golden Zone while setting the workplace
4. Use Gravity instead of Muscle Power – using the muscles to perform the unloading and loading, creates tiredness..use gravity wherever possible
5. Avoid Zig Zag Motions and Sharp Turns in the layout – this may cause fatigue and may lead to accidents 
6. Easy Posture and Easy Motion – No Bending over a worktable to pick a material. Do not place materials in the floor that requires bending and lifting. 
7. Use the feet – Feet can be used to perform a few activities like pressing a foot-switch
8. Materials and tools in front and close to the operator – All tools and materials to be kept in the front and close to the operators. Golden Zone to be followed
9. Arrange the tools and materials in the order of use in the workplace. Check the sequence of use of the tools and materials and arrange them accordingly
10. Integrate Tool Functions to minimize tool variety – combine different nut sizes / screw sizes, so that only a few tools are required in the workplace
11. Use inexpensive types of power – can we use simple mechanical / hydraulic / pneumatic systems for the work, rather than high investment machines
12. Keep the worktables and equipments matched to the operator’s height 
13. Lighting, Temperature and Ventilation to keep the employee comfortable so that the productivity is high
14. All handles and Knobs in convenient places and easy to use shape – recently I saw a trolley where the handle is made of a RTS rod. The ribs are cutting the operator who is using the trolley. 
15. Ensure there is No Oil/Water spillage in the workplace – this may lead to accidents

These points will help you design a workplace that reduces Motion waste in the shopfloor.

#leanmanufacturing #Wasteelimination

What are the points you could identify in your workplace? Share it in the comments.

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