A STUDY ON WASTE MANAGEMENT AND COST

REDUCTION AT ROOTS INDUSTRIES LIMITED

 INDEX
CHAPTER TITLE PAGE NO
iii
ACKNOWLEDGEMENT
vi
ABSTRACT
LIST OF TABLES vii
LIST OF CHARTS ix

INTRODUCTION
INDUSTRIAL PROFILE
COMPANY PROFILE
I OBJECTIVES OF THE STUDY
NEED FOR THE STUDY
SCOPE OF THE STUDY
LIMITATIONS OF THE STUDY

II REVIEW OF LITERATURE

III RESEARCH METHODOLOGY

IV ANALYSIS AND INTERPRETATIONS

FINIDINGS OF THE STUDY

SUGGESTIONS AND
V RECOMMENDATIONS

CONCLUSION

ANNEXURE
i. QUESTIONNAIRE
ii. BIBLIOGRAPHY
 ABSTRACT

The study is an outcome of the topic entitled A STUDY ON

REDUCTION OF LEAN WASTE AMONG EMPLOYEES the survey is company
entitled ROOTS INDUSTRIES LIMITED Located at Chennai . Conversely, the
significance and consequences of non-value-added operations, such as storage,
transportation, and motion, which are typically not made clear. The greatest potential
for cost savings comes from eliminating non-value-added tasks, or wastes, since
doing so may be done without degrading worker happiness. This concept pushes
management to focus more on how critical it is to end non-value-added operations.

The company's main objectives are to identify the kinds and quantities of waste it
produces, calculate the costs associated with that waste, highlight the most effective
waste elimination techniques, maximise profit through waste elimination, and create
plans for continuous waste improvement.

In the research, convenience sampling was employed. To gather the opinions of 120
employees, multiple choice questions have been used. Numerous statistical tools,
such Karl Pearson's Correlation, the Chi-Square test, and the One-Way ANOVA test,
have been used to analyse the obtained data. This study's many fresh discoveries
have helped to provide a few ideas for getting rid of non-value-added waste in the
organisation.
 CHAPTER I

1.1. INTRODUCTION TO THE STUDY

Lean Waste Management is a core idea that stems from Lean Manufacturing and
Management. Its goal is to maximise operational efficiency through the identification
and removal of non-value-adding or superfluous components from a process. Lean
Waste, which has its roots in the Toyota Production System, aims to minimise waste
in order to increase efficiency, save expenses, and provide customers with greater
value. The fundamental concept is on the detection of the "7 Wastes," also known as
"Muda," which comprise excess inventory, waiting periods, overprocessing,
inefficient motion, needless transportation, overproduction, and faults. Organisations
in a variety of industries can increase process efficiency, enhance the quality of their
goods and services, and promote a continuous improvement culture by methodically
addressing and getting rid of these kinds of waste.

Large Indian companies have been trying to adopt new strategies in an effort to
thrive in the new market. Eliminating waste is one of these initiatives that aims to cut
costs by getting rid of non-value-added procedures. The entire company's service,
including paint, computers, furniture, and other supplies, is switching to a new waste
elimination system. The idea being considered is to change the way that servicing is
conceptualised rather than to introduce any new techniques to the way things are
now produced. Finding the different waste categories must come first, then comes
cost reduction or elimination. This is the first step in a successful cost reduction
implementation. Cost reduction targets six wastes: inventory, overprocessing,
motion, waiting, defects, and transportation.
The five wastes that are targeted by cost reduction:

TRANSPORTATION OVER
PROCESSING

FIVE WASTES
THAT ARE
TARGETED BY
COST
REDUCTION

DEFECTS
MOTION

WAITING

WAYS OF ELIMINATION OF WASTE:

• Over-production: Make only what is required, when required, in order to prevent having
too much inventory.Put in place a pull system to manufacture goods in response to
consumer demand.
• Count: By using just-in-time (JIT) manufacturing, you can keep your inventory low.
Put in place efficient inventory control procedures to avoid overstocking.
• Holding out: Reduce downtime by streamlining production procedures and scheduling.
Use fast changeover strategies to minimise downtime in between production runs.
• Transport: Simplify material handling procedures to cut down on pointless movement.
Reduce the amount of distance that materials must travel inside the building by
optimising flow and layout.
• Overprocessing: Cut out pointless processes from the production process and
concentrate on activities that bring value. Review and improve processes on a regular
basis to find and eliminate non-value-added tasks.
• Motion: To minimise needless movement, design workstations with efficiency and
ergonomics in mind.
Standardise work procedures to reduce mobility variances.
• Defects: To find and fix problems early in the process, put quality control procedures in
place. Maintain process improvement to stop faults from happening again.

The 5S.s are some rules for work place company which aim to organize each
worker’s work area for maximum efficiency.
5 S's are:
1. Sort :Sort what is needed and what is not needed, so that the things that are frequently
needed are available nearby and as easy to find as possible. Things which are less often used
or not needed should be relocated or discarded.

2. Straighten : Organise key items for quick access. The goal is to reduce the amount of
movement that is necessary for personnel to perform their duties. For instance, a maintenance
staff member who needs to use various equipment can use an equipments tray. Every item in
the equipment tray is fixed in position so the user can swiftly pick it up without wasting much
time hunting for it. The user can learn about any missing equipment thanks to this
arrangement.

3. Shine :keep machines and work areas clean so as to eliminate problems associated with un-
cleanliness. In some companies, airborne dust is among the causes of color contamination. To
be more aware of dust, some companies paint their working places in light colors and use a
high level of lighting.

4. Stabilize Make the first 3 S’s a routine practice by implementing clear procedures for
sorting, straightening, and shining.
5. Sustain : Promote, communicate, and train in the 5 S’s to ensure culture. This might
include assigning a team to be responsible for supervising complaints with the 5 S’s.

When completely implemented, the 5S technique can improve productivity, raise

morale, make a positive impression on customers, and benefit the organisation. Employee
satisfaction will rise, and the effects of continuous improvement could lead to shorter lead
times, higher quality, and less waste. All of which will improve the marketability and
profitability of your company. Various 5S systems can be used, based on your particular
situation. Many follow a procedure like this:

The programme committee should be established. Each "S" should have a plan developed.
The programme should be publicly announced. Employees should receive training and
instruction. A day to clean and organise the workplace should be chosen. The outcomes of
the 5S should be assessed. Corrective action should be taken.
1.2 INDUSTRY PROFILE:-

The manufacturing industry is a diverse and vital sector of the global economy,
encompassing a wide range of processes and products. Here's an industry profile of the
manufacturing sector:

Overview:
The fabrication, assembly, and raw material processing are only a few of the processes used in the
manufacturing sector to produce tangible items.
In both established and emerging economies, it is essential to innovation, job creation, and economic
growth.

Manufacturing categories:
Primary manufacturing is the process of extracting and initially processing raw materials
(such as those from agriculture and mining).

Secondary Manufacturing:
This process involves turning raw materials into finished goods like textiles, electronics, and
automobiles. Focusesing on the assembly of components or completed goods (such as car
assembly plants), tertiary manufacturing.

Automotive: The production of vehicles, trucks, and the parts that go into them.
Aerospace: The manufacture of spacecraft, aircraft, and related components.
Electronics: The production of electrical products and parts.
Food and Beverage: The preparation and presentation of food items.
Pharmaceuticals: Producing medications and pharmaceutical goods.
Manufacturing of commercial and industrial machines.
Chemicals: Petrochemicals and specialised chemicals are produced in the chemical industry.

Hubs for global manufacturing:

China, the United States, Germany, Japan, and South Korea are well-known global industrial
centres. In addition, a lot of developing nations have turned into manufacturing hubs as a
result of declining labour costs and growing marketplaces.

Automation and technology:

Automation, robotics, and Industry 4.0 technologies have made tremendous improvements in
the manufacturing sector.
These developments increase productivity, lower labour costs, and raise product quality.

Logistics and the supply chain:

The ability of businesses to procure raw materials, oversee manufacturing, and distribute
goods internationally depends on effective supply chain management.
For efficiency, just-in-time (JIT) and lean manufacturing methods are frequently used.

Environmental Issues:
Environmental laws and sustainability are becoming more significant to manufacturers.
Many businesses are implementing environmentally friendly procedures and working to
lessen their carbon footprint.

Regulatory Conformity:
Manufacturers are required to abide by laws governing industry-specific standards for safety,
quality, and compliance.
To protect consumer safety and avoid legal problems, compliance is essential.

World Trade:
Manufacturing is heavily reliant on international trade, and the production process frequently
involves many border crossings.
Manufacturing operations can be influenced by tariffs, trade agreements, and geopolitical
events.

Opportunities and Challenges:

Lack of qualified workers, cybersecurity risks, and changing consumer tastes are problems.
The use of data analytics for predictive maintenance and demand forecasting, as well as
innovation and custom manufacturing, present opportunities.
upcoming trends

Future trends:
Increased automation, 3D printing, environmentally friendly practises, and the incorporation
of AI and IoT technology are all part of the manufacturing industry's future.
In reaction to disturbances like the COVID-19 pandemic, supply chains are expected to
become more resilient and flexible.

The manufacturing sector, which adapts to evolving technologies, consumer needs, and
sustainability requirements, continues to be a pillar of global economic activity. It is still
developing and makes a substantial global contribution to job creation and economic
expansion.

1.3 COMPANY PROFILE:-

1.4 OBJECTIVES OF THE STUDY:-

The main goal of this study is to analysis the current situation of waste
elimination and its important role for reducing the cost.

• To identify the kinds of lean waste in the company inside the premises.
• To observe the methods followed for elimination of waste in the company.
• To provide valuable suggestions and recommendations with regards to improve the
productivity by removing such lean waste.

1.5 Need for the study:-

• Lean Waste is all related to each other and getting rid of one source of it can lead to either
elimination or reduction of cost. There is no question that the elimination of waste is an
essential ingredient for survival in today's world, in that case Company inside the
 premises of ROOTS INDUSTRIES INDIA LIMITED must strive to create high-quality,
and low cost that can get to the possibilities to increase the production process.

• As a result, this research aims to present a complete picture of the reality of wastes
elimination management in its various dimensions in cost-cutting firms and to state the
impact of applying this system to reduce costs in the company, thereby enabling officials to
take action and gain a competitive advantage.

1.6 Scope of the study:-

• The scope of the study is to help for the management to identify the various
kind of lean waste taken place and to take decision to eliminate it.
• This study will not only help me as a student but it also assist the company to
improve it productivity as well as reduce the cost.

• This will be a great step for the further improvement toward production as
well as output that will enhance the management to apply the study in the company.
• This study may be taken as reference for the future studies.

1.7 LIMITATION OF THE STUDY:-

The numbers of respondent’s are restricted to 150 only.

• The responses were gathered from the company's machine operators since the study had to
overcome a number of challenges and barriers linked to its subject matter in order to
accomplish its goals and provide answers to the questions addressed.

• Additionally, the data obtained for the study is entirely based on original data provided by
the respondents, who believe that any information pertaining to their company inside is
confidential and should not be shared with others.

• There is a potential of personal bias when using primary data. The accuracy might not be
accurate.
 CHAPTER II

REVIEW OF LITERATURE:-

• Jafri Mohd Rohani(2019) note the color industry's use of value stream mapping for
production line analysis. Through the formation of teams, the selection of products,
conceptual design, and time estimation, waste is identified and eliminated in this
article. Several lean strategies were used to reduce the lead time from 8.5 days to 6
days and the value-added time from 68 minutes to 37 minutes.

• Tomas Rohac et al. (2018) made a value stream map to demonstrate how to use lean
methods, like the Ishikawa chart and the 5-why, to plastic health care products in
order to improve inventory control and shorten lead times.

• Dinesh Seth(2018) A methodical technique is used in lean manufacturing to find

inefficiencies and continuously improve upon them. This article uses the value stream
mapping technique to reduce waste in the cotton seed oil sector. This study's
evaluation of the cotton oil seed sector makes use of an Indian sample, a prepared
question sheet, and information from emails and phone calls. An overall map of the
supply chain was constructed, and waste was then found, altered, and eliminated to
increase production.
• Jennies angelis et, al.(2022) Lean is an internationally competitive standard for discrete
part product assembly. The rank and file's capacity for evolutionary problem-solving is a
prerequisite for successful Lean implementation. This alone depends on staff participation in
development initiatives and the application of suitable procedures.

• Worley (2019) The methodical elimination of waste from every aspect of the value chain by
every employee of the organisation is known as lean manufacturing.
• Shah and Ward (2010) Lean is a management philosophy that focuses on finding and
removing waste across the whole value stream of a product, which includes both internal
corporate processes and supplier chain network processes.
• Taj and Morosan (2020) A multifaceted strategy that includes waste-free production
(JIT), uninterrupted and continuous flow (Cellular Layout), well-maintained machinery
(TPM), a well-established quality system (TQM), and an empowered and well-trained
workforce (HRM) that improves operations and competitive performance (quality, cost, quick
response, and flexibility).

• Boppana v. chaudhary et, al. (2022), This paper aims to illustrate how lean
manufacturing may be used in a pharmaceutical company using the case study of the
creams and ointments product line. The incapacity to create goods and fixed operating
expenses were other industrial issues. In order to optimize operations, this study
identifies waste-producing problems using lean manufacturing and VSM as a lean
tool. It is simpler to discern between processes that bring value and those that don't
thanks to a mapping technique called VSM. Draw a map of the current situation and
use the 5-why method to collect data. then use the 5s tool to develop a future state
map for improvement.
• Chaple (2019) Examine the factors that facilitate or hinder the application of lean
concepts and lean dissemination in the manufacturing sectors of India. The findings
indicate that lean evaluation is currently the main area of study for lean
manufacturing. In order to evaluate the degree of lean implementation, justify
expenditure above lean implementation, and respond to particular queries from
various levels of management responsible for lean implementation, leanness draws
attention. He developed multiple criterion decision-making (MCDM) for lean
assessment in order to evaluate lean performance comprehensively and the popularity
of lean in India; nevertheless, success is still at the beginning of the journey. There are
more industries in India with medium to low lean diffusion besides the automotive
and electronics sectors.
• Pratik Chikhalikar (2018) The adoption of lean in the Indian engine production
plant was the main focus of the study. Through research, the essential lean tools and
the schedule for putting them into practice were found. A study found that the
following factors influence the application of lean: A number of aspects need to be
addressed, including poor inventory management, bottleneck operations, poor
 information flow, problems with material flow and transportation, JIT, Kanban,
Kaizen, TPM, 6 sigma, 5S, and single minute swap of die.
• Rakesh kumar (2015) conducted a study to determine the importance of Lean
Manufacturing components for the Indian manufacturing sector.
• Vikas kumar ( 2 0 2 2 ) The study lists the advantages realised, the main challenges
encountered, and the negative effects, which include excessive cost cutting,
abnormally low inventories, an excessive reliance on Lean guidelines, harm to one's
physical and mental well-being, harm to society, and poor product quality.
• Sudipta Chowdhury (2019) conducted studies to boost the furniture manufacturing
industry's productivity in India. Several lean methodologies were applied, such as
Short Interval Control, Gemba (The Real Place), and Single-Minute Exchange of Dies
(SMED). The final result demonstrated a notable increase in both the amount of
money and the rate at which different lots were handled. Additionally, the study
demonstrates that an increase in total equipment effectiveness was associated with a
2.26 multifactor productivity. This study revealed that lean techniques can be
effectively applied in the furniture manufacturing sector.
• George L. Hodge et al(2022) did research to find lean tools for the textile industry in
the US to reduce waste and non-value-added activities and improve customer
satisfaction, The author identified the following obstacles to implementing lean
manufacturing: resistance to change on the part of management and shop floor staff;
reluctance on the part of shop floor staff to suggest improvements; a gap between
marketing, sales, product development, and shop floor staff; and the need for
multilingual training due to the lack of native English speakers on the shop floor.
• Neha Verma (2017) carried out a study to find waste-related problems, such as
bottlenecks and the reasons behind equipment failure, and address them in small-scale
businesses' adoption of lean manufacturing. Process analysis concentrated on
controlling rejection, inventory, waiting, and set times in addition to reducing non-
value-added time and activities. Only the techniques and layouts were altered in this
study to facilitate the product's easier passage through the manufacturing process. No
additional equipment was bought, and workers were not pressured to work longer or
tougher hours.
• Dave et al (2020) study deals with Lean Construction along with information and
communication systems. Study reveals that by adopting techniques such as process
modelling, lean principles and process analysis techniques, the manufacturing
 industry maintains a well performing process.- process standardization across the
industry will highly effective and efficient.
• Rahul Sindhwani (2019) According to a study, LI would strengthen the bond
between manufacturers and consumers by satisfying their most recent demands.
Overproduction, Processing Waste/Over Processing, Transportation, Waiting/Delays,
Inventory Waste, Motion Waste, and Defects are the typical seven metrics that are
employed. Pull system/KANBAN, VSM, and 5s were the methods and tools that were
used to eliminate wastes.
• Sindhwani (2020) The bottom frame's production rate was enhanced by
implementing the lean and agile principles of one piece flow, pull system, and value
streaming. The pull system was used to determine that the production rate needed to
be raised. To accomplish the needed cycle time, one piece flow and VSM were used
to determine the restrictions.
• Ramune (2017) Research highlights the difficulties and impediments that must be
surmounted in order to apply the lean approach. "Lean" enterprise, or simply "Lean,"
is a methodology that views any use of resources for any purpose other than
producing value for the final user as waste that should be eliminated.
• Ciarniene (2019)Three categories of impediments are identified by research: issues
related to people, processes, and sustainability. The study recommended using the
tools and approaches first rather than giving personally relevant concerns more
thought.
• Gulshan Chauhan(2022) Research demonstrates the operation of waste reduction,
JIT, and CI. The driving forces behind lean manufacturing (LM) include vertical
information systems, function integration, decentralisation, multifunctional teams,
pull, JIT deliveries, zero defects, continuous improvement, and waste removal. JIT is
prioritised, then CI. He assesses the importance of implementation using the SPSS
correlation method.
• Sourabh Sharma(2019) The primary objective of the study is to ascertain the
possible advantages and restrictions of lean standards and certification in order to
decide whether or not standardisation would be beneficial in putting lean ideas into
practice. Therefore, the organisation should first understand from lean practitioners
how standardisation would help to remove major issues in integrating lean tools and
their concepts before conducting the survey.
• Sharma(2018) Through surveys, they get the chance to gauge the distinct objectives
and motives of every industry and lean professional. Lack of experience with
implementation is the primary problem with lean. Middle management pushback and
employee opposition.
• Kashif Mahmood(2017) research aims to provide a better understanding of LP
approach in order to enhance productivity, reduce cost and maximize customer value
while minimizing waste during the production processes. "Productivity is a
relationship (usually a ratio or an index) between output (goods and/or services)
produced by a given organizational system and quantities of input (resources) utilized
by the system to produce that output‖.
• Mahmood(2019)The input are usually classified as labor, capital, material
(inventory) and energy. Successful lean efforts are – Quality, Cost, Flexibility,
Delivery reliability, Delivery time. Other factors that makes lean more effective and
related to strengthening the workforce‘s welfare, driving force, motivation and
influence.
• Mohammad Obeidat (2023) The report states that the five types of waste that are
identified and examined using VSM in the sewing line are defects, inventory,
overproduction, transportation, and waiting time. Lean manufacturing techniques
include line balance, layout redesign, and quality at the source. By examining how
implemented lean methodologies affect output, a more accurate value stream map for
the future is produced.
• Obeidat (2022) Results show a 96% reduction in manufacturing wastes in addition to
a 43% lead time reduction. Here, processing costs must be computed and process
metrics supplied. Line productivity is determined by the number of workers on the
line and the duration of the product cycle. Separate calculations will be conducted for
work efficiency, work station targets, and line targets in order to increase staff
productivity.
• Wagner Cezar Lucato (2023) The study looked at the performance of the Lean
implementation across 51 industries of different sizes, across a variety of industrial
segments, and across national and international enterprises using two concepts: the
degree of leanness (DOL) of a J4000 piece and the DOL of a company. To ascertain
the relationship between DOL ownership, firm size, and the pertinent industrial
sector, three additional hypotheses were assessed.
• Lucato(2022) Talk briefly on the benefits and limitations of LI. The factors under
examination are: Product, Process Flow, Supplier/Organization/Customer Chain,
Information, People, and Management/trust. To verify the measurement's validity,
more research comparing the DOL measurement used here with other LI
measurements of a similar kind should be done.
 CHAPTER III

RESEARCH METHODOLOGY

3.1 RESEARCH DESIGN:

The type of research design used in this study is descriptive research. The
Objectives of the descriptive research is to bring the problem in to focus and produce a
rigorous definition

3.2 METHODS OF DATA COLLECTION:

Two types of data collection methods are used for this study.
i) Primary data
The first-ever and newly gathered primary data are those that are considered to be
original in nature. Inside ROOTS INDUSTRIES INDIA LIMITED's facilities, primary data
for this study will be gathered from personnel and employees of a certain department.

ii) Secondary data

Collections of secondary data like process, procedures, implementation etc., were
taken from various books published on Company Waste Management, journals and related
web sites.

3.3 POPULATION AND SAMPLE SIZE:

Population:
The population for the study is the employees of company inside the premises of
ROOTS INDUSTRIES INDIA LIMITED
Sample Unit:
 The sample units are the employees of company inside the premises of ROOTS
INDUSTRIES INDIA LIMITED
Sample size:
The sample size is 150.

SAMPLE DESIGN:
An established strategy for drawing a sample from a certain population is known as a
sample design. It describes the methods or processes the researchers use to choose the items
for the sample. The research selects the samples using an easy sampling approach.

3.4 TOOLS USED FOR ANALYSIS:

The tools for this study is
 Simple percentage analysis.
 Chi-square analysis.
 ANOVA

PERCENTAGE ANALYSIS:
A particular kind of ratio is a percentage analysis. In order to compare two or more data
series, percentages are employed. Percentage is used to describe relationships and can be
used to compare distributions of two or more data series in relative terms.

ONE-WAY ANOVE:
To ascertain whether there are any statistically significant differences between the means of
three or more independent variables, one-way analysis of variance is utilised. It can also be
used to compare whether or not the means of two samples are substantially different.

CHI-SQUARE ANALYSIS:
One crucial non-parametric test is the chi-square test. It can be used as a test of
independence as well as a test of goodness of fit, and for each test, the observed and predicted
frequencies must be grouped similarly. Additionally, the theoretical distribution must be
modified to produce the same total frequency as that found in the case of the observed
distribution. The formula for 2 is then as follows:

2
2 ∑(O−E)
x=
E