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The Seven Forms of Waste Continuous Improvement focuses on
the identification and elimination of the 7 forms of waste:
Overproduction Inventory Unnecessary Motion Transportation Waiting Over Processing Defects / Repair / Rework
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1. Over ProductionProducing products or materials before they are needed.
Overproduction is the worst form of waste because it is the root cause of many other wastes.
Results of Over Production: • Products being produced in excess quantities• Products being made before customers need them• Excess Inventory• Excess Transportation• Hides available capacity
Caused by:• Working ahead of customer (internal/external) or process requirements
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Waste Of Overproduction : Example
OPERATOR SHOULD BE IN THIS STATION (ST 16) BUT IS WORKING AHEAD IN ST 15
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2. Inventory
Excess inventory is not directly required for current customer orders.
Results of Excess Inventory:• requires space• costs money and ties up capital• search and transport damage• hides defects• excess WIP and finished out-of-date product• Increased deterioration
Caused by: • Working ahead of build requirements• High WIP standards• No WIP standards• Lack of JIT/Pull system
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3. Motion
Unnecessary movement in a process.
Some Results of Motion:• unnecessary walking• poor ergonomic conditions• part transfer• reaching and stopping and walking to locate/ pick up parts/tools
Caused by:• poor parts placement• poor process flow• poor work station layout
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Waste of Motion: Example
TEAM MEMBER IN PAINT SHOP ATTEMPTING TO UNTANGLE HOSES TO THE BACK-UP GUNS IN THE TOP COAT BOOTH.
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4. Transportation
The unnecessary movement of materials
Results of Transportation:• Loss of traceability • Damaged goods• Increased Lead Time• Excess Costs• Storage space
Caused by: • Poor parts storage• Poor Work area layouts• Working ahead of build requirements• Lack of JIT/ Pull system
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Waste of Transportation: Example
BODY SHOP T/M CARRIES PARTS TO RACK LINESIDE.
BODY SHOP CONVEYANCE DELIVERS AMS BRACKETS TO TABLE ON THE FLOOR
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5. Waiting
Periods of inactivity in a downstream process that occur because an upstream activity does not deliver on time.
Results of Waiting:• Over Production• Over Processing• Idle resources• Non-Value added work
Caused by:• Line stops• Waiting for Material• Repair/Maintenance• Waiting for equipment to process• Missing tools• Non- “Full” work process
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Waste of Waiting: Example
TEAM MEMBER WAITING ON BODYIN ST. 3900. ROBOTS IN ST. 2400 WENT DOWN CAUSING DOWNTIME
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6. Over Processing
Producing more or better than the customer requires.
Results of Over Processing:• Increased Processing Time• Costs• Incorrect process/equipment
Caused by:• Refining the product in ways or areas not important to the customer• Wait Time• Unclear Quality Standards
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7. Defects/Repair/Rework
Products or aspects of the production processes that do not conform to specifications or to the customer’s expectations.
Results of Defects/Repair/Rework:• Customer Dissatisfaction• Non-Value added work• Extra costs• Extra space• Extra inspections/checks
Caused by:• Scrapped parts• Wrong or defective tools or machines• Wrong or missing processes• Poor Problem Solving• Unclear Standards
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