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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requires space• costs money and ties up capital• search and transport damage• hides defects• excess WIP and finished out-of-date product• Increased deterioration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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Excess Inventory: Example

STANDARD SET AT 4 HIGH X 3 DEEP PART BIN STACKED 6 HIGH

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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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Waste of Over Processing: Example

BODY SHOP T/M SANDING DOOR THAT HAD NO DEFECTS

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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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Waste of Repair: Example

PAINT SHOP T/M MAKING REPAIR IN SPOT REPAIR BOOTH.