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Manufacturing yields and efficiency can often be greatly increased by reducing the level of scrap and rework, which is produced in virtually all manufacturing processes.

Scrap is generally product that is of poor quality, defect, reject, faulty, imperfect or may require rework to bring it up to an acceptable standard.

There is a cost of poor quality (COPQ) attached to all scrap and rework and scrap reduction in turn reduces costs and improves efficiency.

Why is scrap produced?

The production of scrap product can be due to;
  • Imperfect product being produced when a machine or process is starting up or shutting down; before or after a changeover, setup, breakdown or maintenance.
  • Defective parts or operation
  • Poor, late or ineffective maintenance
  • Poor process monitoring and lack of correct reaction to process problems

PlantRun OEE & Downtime Monitoring systems can provide highly accurate scrap and rework figures in real time. Scrap products can be counted or quantified as they occur and assigned reject or defect reasons. This information can be displayed on systems screens and used to trigger alarms if required.

Reports can be generated in real time showing detailed scrap analysis. This could be scrap produced over any time period, like an hour shift, day, month, year etc. or you may want to analyse the scrap levels of a specific product, machine or operator etc.

The relative cost of good quality and scrap product can also be calculated automatically by the system as well as other manufacturing KPI's. Read more about the benefits of Downtime Monitoring Systems

If you have a scrap reduction project and would like further information on how PlantRun systems can help you please contact us