Developing a Waste Stream Map to Lean-out Waste Handling Operations in a Manufacturing Setting

Book excerpt: The objective of this research project was to describe the current state of waste streams, identify flow patterns, recognize improvement opportunities, and recommend alternatives for waste handling throughout the window manufacturing process at Company XYZ. Due to the improper handling of the waste generated at different stages of the manufacturing process, the company incurred in significant operating costs. This project proposes improvement measures through the adoption of lean manufacturing tools to identify process deficiency indicators; striving to standardize the waste management process, achieve greater efficiency and cost reduction opportunities that enhance the company's bottom line. This was done by exploring applicable lean methodologies. Value stream mapping was utilized to identify the flow of byproduct waste throughout the manufacturing layout, data collection charts were used to quantify the amount and proportion of waste generated throughout the manufacturing process, and 5S methodologies coupled with visual management techniques were applied in order to contribute on the categorization of waste and ultimate uncover treatment alternatives. Most significantly, this project identifies a direct correlation between proper waste handling procedures and cost reduction opportunities, ultimately having a positive impact on the company's bottom line.