Smart SCRAP management: Reduce costs from day one
Learn in this article what scrap is, why it occurs and how to reduce it with Kapture.io’s SCRAP tool.
What is SCRAP?
Scrap is material or units that are discarded during manufacturing because they do not meet quality requirements. It can be out-of-tolerance finished product or unusable parts/components due to process errors. It is usually caused by machine misalignments, human error, misapplied instructions, incorrect process parameters or raw materials that do not meet specification.
Its presence implies waste of raw material, time and energy, in addition to added costs for waste management, rework, downtime and logistics. In terms of indicators, it has a direct impact on PPM, FPY and Cost of Quality.
Why is SCRAP a key improvement opportunity?
In an industrial environment where every penny counts, reducing SCRAP is one of the most direct ways to reduce production costs.
The key is to have clear, accurate and real-time information to anticipate errors and make intelligent decisions.
This is where Kapture.io makes the difference: its SCRAP solution is designed to facilitate the capture, visualization and analysis of scrap directly from the plant floor, without the need for complex development.
You can see an introduction to the Kapture.io tool in this video:
SCRAP tool in Kapture.io
Kapture.io ‘s SCRAP tool is designed for manufacturing companies looking to reduce waste quickly and efficiently.
Although it was initially conceived for plastic injection molding industries, today it is easily adaptable to any production process with high levels of rework or defective parts.
Its implementation is agile , visual and without additional developments, it can be operational in less than a week. Learn more below:
1) Data entry form
It allows information to be captured directly from the production area, without the need for spreadsheets or complex systems:
Main characteristics:
- Intuitive introduction from a web browser.
- Capture scrap/rework by: reference, family, shift, mold, cavity, material, etc.
- Configurable manufacturing attributes.
- Reports by shift, batch, frequency or specific condition.
- Adaptable visualization according to the type of defects and processes.
2) Intelligent Data Visualization Dashboard
All the information collected is automatically transformed into dynamic dashboards that facilitate decision making:
Includes:
- Total scrap cost and time evolution (weekly/monthly/quarterly).
- Top 5 most frequent defects.
- Analysis by product, machine or material family.
- Visual comparisons between plants, shifts or production lines.
- Potential savings panel for scrap reduction.
Benefits of implementing SCRAP with Kapture.io
Knowledge is the first step to reduce costs. Once we can resolve and analyze manufacturing quality, we can then intervene with corrective actions to reduce the production of defective parts. In less than a week we can implement the SCRAP solution that allows you to:
- Dynamic comparative analysis between parts, batches, machines, shifts, operators…
- Scrap control during production, start-up, micro-stops, alternative material testing, etc.
- Problem identification (cooling, hot chamber blockage, filling, compaction…)
- Functional diagnostics in multi-cavity molds.
- Performance of duplicate molds for high production rates.
Visible results from day one with Kapture.io
Kapture.io transforms your SCRAP control process into a living, visual and intelligent system. What used to take days of manual review is now instantly available in a clear, accessible and actionable dashboard.
