Awareness panels – scrap cost

Problem solved

Lack of awareness of the actual financial losses caused by scrap product and need for a manual offline excel cost reporting. 

Implementation

- Each line was divided in to logical segments and scrap counters identified for each, both as an actual reject points or calculated reject points (infeed-outfeed logic).

- To each counter a currency conversion factor was assign based on the production stage on witch the product is scraped.

- For each line a Live Dashboard was created with scrap cost indicated over a line layout.

- In parallel the scrap cost is saved same way as standard counters and available for any reporting.

Benefit

- Cost awareness among employees

- Direct feedback of scrap costs

- Cost available in standard reports

- Backbone for future PDCA analysis