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Lean-Insight.comLean Six Sigma Training
Part 8
Training Centers: Bangalore, Chennai and Hyderabad
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Waiting Cont.
Symptoms: People waiting on systems (e.g.
copier) People waiting on others
Sign offs Edit Client input Compliance / legal
Lack of information to complete a process
Delay in the upstream process step
Causes: Inconsistent work methods Poor process/person effectiveness Inefficient process Inappropriate metrics Lack of training
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7. Transportation
Information Generated
Entered
Filed
Sent to the Plant
Verified
Filed
Approved
Entered
Returned
Excess movement of what flows in the process. This can be the product material or documents.
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8. Intellect/ Unutilized skills
Symptoms: Few improvements 99.9% is good enough Doing MY job mentality Lack of employee involvement Lack of team activities Poor morale
Causes: Blame the person, not the process
(focusing on who made the error, not why the error occurred)
Hide the problems Status quo never challenged Poor suggestion program Lack of accountability
Definition:Any failure to utilize the
time and talents of the people
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Overproduction
Inventory
Extra Processing
Motion
Defects
Waiting
Transportation
•Processing before next operation is ready•Processing prior to need•Making decisions too early
• Multiple credit applications awaiting approval• Unnecessary document / data storage
• Navigating multiple screens to input data• Multiple ways to do the same task• Printed material• Duplicate entries• Navigating multiple screens to input data• Printing Material• Ergo…walking, bending, twisting• Looking for data / info• Personal data incorrect• Missed customer due dates• Data entry errors• Rework• Credit applications awaiting approval• Info awaiting an overnight “systems batch run”• Manual decisions• System downtime / response time
• Delivering hard-copies• Shipping hard-copies requiring signature
•Sub assemblies and components between feeder & main lines
•Material between operations & process steps• Inventory stored in warehouses•Buffer & safety stock inventory
• Planned re-work• Un planned re-work• Handwork…polishing, deburring
•Operators bending, turning, twisting, reaching, walking•Machines “cutting air”•Robotic motion “getting back to home”• Poor quality of materials• Equipment failures• Missing customer due dates…internal & external•Operators waiting•Machines waiting •Customers waiting
•Conveyance of any materials, tooling•Conveyance systems
What is Waste?…Examples
8 Wastes Product Flow Knowledge Flow
Unutilized Skills: Any failure to utilize the time and talents of the people
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Find examples of the 8 Wastes in your operation
Motion
Transportation
Over Production
Inventory
Waiting
Processing
Correction
Waste Scavenger Hunt
Unutilized skills
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Lead Time
Value Added
Non-Value Added
Non-Value added activity increases lead times, adds cost, creates opportunities for defects, increases inventories, and inhibits Flow Production.
Value Added vs Non-Value Added
Start End
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New Lead Time
Lean tools help us identify and eliminate waste from our processes, leading to: Reduced costs Reduced lead time Faster response Improved quality Reduced inventory Reduced floor space Better predictability
Lead TimeWaste Waste
Compress the time
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Lean-Insight.com
If you are looking for Lean Six Sigma training along with certification in Bangalore visit: http://lean-insight.com/six-sigma-training-bangalore/
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