A systems engineering methodology for manufacturing waste minimization

Reducing waste in our manufacturing environment has become a major area of focus across the corporation. We are developing methodologies to characterize and reduce the environmental impact of our manufacturing processes. As a starting point, we have conducted waste minimization audits, which typically consisted of two steps. The first step was to gather data on energy, material, product, and waste flow and their associated costs. The second step was to develop a thorough process characterization. To pursue these activities, we interviewed process and product engineers, reviewed paper and electronic central databases, and examined the real manufacturing operation. The results of these audits highlighted the expenditure of resources and helped identify options for waste minimization activities. When exploring options for waste reduction, determining their cost-effectiveness isn't always straightforward. Modeling can be a useful tool in this regard, because it can simulate alternative processes or systems and optimize new or current processes.