2225 LeanManu Muda Presentation Demo

8/11/2019 2225 LeanManu Muda Presentation Demo

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The 8 wastes in Lean (Muda)Waste covers allactivities that do notcreate any value forcustomers.

In Lean the term Mudais used about waste.

Up to 95% of theactivities in a typicalcompany do not createvalue for customers!

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Table of contents What is waste the 8 types 3

Results by reducing waste 5

The wastes - reasons,consequences and tools 6

Waste and implementing Lean 31

Related Lean tools 34

The presentation hasfocus on the 7 normaltypes of waste and themost common 8th

form of waste.

The presentation isgeneral for the typesof waste in a

manufacturingenvironment.

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What is waste? Waste in Lean is an overall term for

all the activities that do not add any

value for the customers. Many use the term Muda for waste.Muda means waste in Japanese. By

using the word Muda there is a cleardistinction between normal waste andrubbish and actual loss on processes.

In typical companies60% of all activitiescan be categorized aswaste. Another 35%

are necessary due tostructure etc. but stillwaste. Only 5% addvalue!

60%Waste

35%Necessary

waste

5%Value

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The 8 types of waste in LeanUnexploited knowledge

Lack of exploiting theknowledge and talent of the

employees.

Motion

Unnecessary movementof people or parts within a

process.

Rework

Sorting, repetition ormaking scrap.

Overproduction

Producing too much, tooearly and/or too fast.

Transportation

Unnecessary movement ofpeople or parts between

processes.

Inventory

Materials parked and not having valueadded to them.

Over-processing

Processing beyond thedemand from the

customers.

Waiting time

People or parts waiting for awork cycle to finish.

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Results by reducing waste Increased capacity and productivity.

Shortened lead time.

Improved cash flow. Improved and stable delivery service.

Fewer injuries.

Improved safety level.

More satisfied employees.

The focus on reducingwaste is one of thekey elements in Lean.

Lean is about creatinga culture ofcontinuousimprovements. Aconstant focus on

perfection. Onminimizing waste inthe organization.

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The 8 wastes in details In the following slides the 8 types of

waste are presented:

Presentation of each waste. Reasons for this type of waste.

Consequences of this waste.

Tools to minimize this waste.

Typical reasons foreach waste.

Typical consequences

of each waste.

Tools to handle and tominimize each waste.

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Transportation Reasons Production layout according to depart-

ments. Parts and people must movebetween departments.

Production is based on storage ofparts between processes due to plan-

ning or imbalance in process times. Distance between companies in the

supply chain (suppliers/customers).

Transportation: That parts are moved

unnecessarilybetween machines

and/or machines andstorage. That parts are moved

unnecessarilybetween companies.

That employees mustmake unnecessarymovements betweenmachines orprocesses.

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Transportation Consequences Unnecessary time spent on handling,

transportation, managing etc.

Increased safety risk during transpor-tation specially in a production area.

Increased risk of scrap due to dama-

ged goods, influence of weather etc. Increased inventories and risk of

unsaleable products.

Transportation is avery visible type ofwaste in a production.

Many companies buy

parts overseas due tolower price. But oftenthe benefits arereduced due to themany wastes caused

by overseas sourcing.

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Transportation Tools Flow between processes.

Implementing flow reduces the needfor transportation dramatically.

Parts located as close to the point ofuse as possible.

Use local suppliers. Specially onparts where the demand fluctuates.

Internally in a produc-tion area reducingtransportation is aboutgood management,

flow and layout. Externally, reducingtransportation is aboutminimizing unneces-sary transportation.

Often transportationleads to urgent ordersdue to fluctuation indemand or qualityproblems.

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Remaining slides in full version! Inventory Reasons Inventory Consequences Inventory Tools Overproduction Reasons Overproduction Consequences Overproduction Tools Waiting time Reasons

Waiting time Consequences Waiting time Tools Over-processing Reasons Over-processing Consequences Over-processing Tools Rework Reasons

Rework Consequences Rework Tools Motion Reasons Motion Consequences Motion Tools

Unexploited knowledge Reasons Unexploited knowledge Consequences Unexploited knowledge Tools Waste and implementation of Lean Train in seeing waste! Continuous reduction of waste Related Lean tools

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2225 LeanManu Muda Presentation Demo