How to Reduce Waste in Industrial Operations

Waste is a major environmental and health issue — especially in the US, which produces the most plastic waste in the world per capita or 130 kilograms per person. 

At the same time, inefficient waste management is a bottom line issue for manufacturers, with excessive material use, inefficient operations, and outdated processes leading to higher overall costs. 

In this article, we will outline waste reduction procedures to help manufacturers fix both of these problems. 

Identifying Waste

The first step to reducing waste is understanding where it comes from. Here’s how professionals categorize industrial operations waste by source: 

• Material waste – This type of waste is mostly caused by overproduction and inefficient packaging. It creates scraps and unusable materials.,
• Energy waste – Energy waste is caused by inefficient or outdated manufacturing processes, or even poor scheduling.
• Defective products – Manufacturing and packaging errors lead to products that cannot be sold. Unfortunately, they usually end up in landfills.

As a business owner, you should first analyze your processes to see which area is problematic and in what way. Then, you can start creating solutions.

Waste Audits

Your next step is to conduct a waste audit and see how to resolve the issue. Companies often find plenty of waste that could have been recycled or reused, purchasing issues, and management decisions that increase waste. 

Waste audits consist of four main phases:

• Identifying inefficiencies in the workflow
• Measuring and sorting waste (by material and type)
• Analyzing data
• Finding solutions

At the end of an audit, companies often improve their recycling practices and frequently train their staff to reduce waste and the costs of waste. 

Lean Manufacturing 

Lean manufacturing is an organization framework which aims to maximize value while minimizing waste. It helps you resolve inefficiencies in your supply chain, which may involve anything from material waste to time waste and underutilization of talent.

Its key principles include: 

• Continuous improvement – Analyzing processes to find room for improvement.
• Just-in-time production – Producing only what is needed, when it is needed. 
• Standardized workflows – Keeping tasks consistent and well-organized to minimize errors (and chances of defective products).

While these principles are useful, experts advise against following them blindly, as they come with some disadvantages. For example, they may create additional pressure on workers and cause burnout, which again, leads to errors. 

Sustainable Materials

Recyclable or biodegradable materials are becoming more popular each year, especially as we learn more about the impact of microplastics.

However, there is another way to approach materials sustainably, and that is simply reducing packaging. Many companies aim to cut any unnecessary use of materials in the supply chain, especially if switching to more sustainable materials isn’t cost-effective for them.

Automation

Automation is one of the best ways to reduce material and energy waste. At the same time, it can improve worker wellbeing by easing their workload, allowing workers to focus on quality.

It can be used in various stages of the production process. For example, in packaging, automated systems ensure consistency, minimize human error, and reduce material waste. Custom packaging machinery can be optimized precisely for the product you need.

Packaging Design

Sustainable packaging design can not only decrease your material waste, but also reduce your energy waste, transportation costs, and make for a more efficient workflow.

So, what are some common changes in design that make packaging more sustainable?

If it’s viable and safe, business owners often choose more lightweight or eco-friendly materials. Another way to improve design is to rethink the shape and size of the packaging — consider materials that are easier to stack during transportation, and you may reduce the number of shipments you need.

What Are the Long-Term Benefits of Waste Reduction?

Apart from cost-efficiency and environmental benefits, waste reduction lets you appeal to eco-conscious consumers. And not just to them. Your business can also build a more positive reputation among employees, stakeholders, and other business owners. 

An additional benefit comes from improving your workflows. When you address inefficiencies, you may achieve faster production times. This increases your output, reduces idle time and waste, and may even let you deliver products more quickly.