Scrap Reduction Using Lean Manufacturing and Six Sigma Tools.

Scrap Reduction - how to avoid the scrap


In this article, you will learn what is a product reject and how to make scrap reduction using lean manufacturing and six sigma techniques.

Scrap Definition

Rejects or scrap is the discarded material from an operation suitable for reprocessing or not.

Scrap and rejects are byproducts of an inefficient process that promote rework activities.

Scrap can be very expensive, as it can be leftover materials in excess of those needed for an assembly, or could be an entire batch of parts outside tolerances that need to be reworked or recycled.

The Principal 7 Causes of Scraps, Rejects, and Rework are:

  1. Machine malfunction
  2. Human error
  3. Poor quality materials
  4. Weak designs
  5. Specifications change not communicated
  6. Inefficient quality systems
  7. Lack of procedures and process understanding

These causes can be reduced and in most cases, preventable with the right processes, systems, and training.

Seven 7 Suggestions to Make a Scrap Reduction in your Manufacturing Operations.

  1. Establish a complete BOM Bill Of Materials for each product.
  2. Select the right raw materials and suppliers based on quality and not on price exclusively.
  3. Perform a trusted cost and process analysis of your operations.
  4. Implement a visual inspection system to detect components and product failures as soon as possible.
  5. Automate the scrap movement and disposition.
  6. Bring frequently training to your personnel.
  7. Establish efficient communications between the design and production members.

six sigma definitions

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CIQA is a quality and regulatory consultant with 25 years of experience developing products and managing projects in the medical device supply chain, and pharmaceutical industries. Rest assured of the safety or being in the right hands.

Our Lean Manufacturing team could provide you a broad range of professional expertise implementing these techniques and tools.


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Quality procedures templates

Three (3) Options to Create Document Control Management DCM Procedures:

Bronze Option. You Can Create Your Own Quality Procedures, using a Template.

You can download samples of the Document Control Management DCM procedure templates in .pdf format. 

To see the complete list of the most popular quality procedures templates, click here.

In addition, you can request a quotation to buy online a full SOP template document in MS Word format that is completely editable, ready to fill, and adapt to your specific needs.

Silver Option. We Can Bring You Formal Training about Scrap Reduction.

This option is recommended if you want to learn more about how to build robust quality system procedures. One of our expert(s) can provide online step-by-step training to your team (unlimited assistance) on how to build reliable SOPs using our template(s). Also, you can improve your corporate quality procedures and policies by incorporating our template(s) and tools.  It includes a fully editable template from the Bronze option, plus training, exams, and a training certificate for each assistant.  Request a quote now.

Gold Option. We Can Create Customized Quality Procedures.

One of our expert(s) will create and prepare your customized SOPs with the inputs and specific information of your company. It includes a fully editable template from the Bronze option, plus online support in document creation, implementation, and training. Request a quote online.

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REFERENCES: Scrap Reduction.





Picture of Ramon Cayuela, MS, BS, Chemical Engineering

Ramon Cayuela, MS, BS, Chemical Engineering

CIQA President and CEO.
I've been working in validation engineering since 1992 with many multinational pharmaceutical companies. I love sharing my passion and knowledge with others. If you have any questions about anything (or just have general questions). I will be more than happy to assist you. You can count on the BEST customer service on CIQA. I go to great lengths to make sure my clients are 100% satisfied with their purchases and check emails/messages consistently throughout the day. You can rest assured that everything being sold here is as-described or your money back. I look forward to working with you!