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This is a step by step guide to reduce waste in a process. It is simple and easy to implement. It starts with identification of waste, through cause prioritization, solution generation and selection and implementing control measure to manage waste.
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Waste Management
For assistance call: Amandeep Singh Gujral
+91-78375-43000 Industrial Engineer
What is Waste?
• Any resource or activity which adds no value to the output is waste.
• Anything which leads to error, defect and injury is considered waste.
3 Major Categories of Waste
• Mura-Unevenness
• Muri-Overburdening
• Muda-7 types of waste.
Types of Waste
• There are 7 types of waste:
Transport Inventory Motion Waiting
Over processing
Over production
Rework
TIMWOOR Matrix
TIMWOOR Matrix
Process Name: Process Location:
Types of Waste: Describe Waste Cause of Waste Solution Control
Transport
Inventory
Motion
Waiting
Over-Production
Over-Processing
Rework
TIMWOOD table is used to identify the types of waste hidden in each process. Starts with defining the waste then identifying the cause and their possible solutions and finally control plan.
Description of Waste
Identification Of Waste
Typify waste
Step Wise approach to identify Waste
Process Walk Through
Process Walk Through Process Name Process Location
Steps Description VA/NVA Type
1
2
3
4
5
6
7
8
9
10
All non-value added steps are waste. Next step is to typify the waste according to TIMWOOR.
TIMWOOR Matrix
TIMWOOR Matrix
Process Name: Process Location:
Types of Waste: Describe Waste Cause of Waste Solution Control
Transport
Inventory
Motion
Waiting
Over-Production
Over-Processing
Rework
TIMWOOD table is used to identify the types of waste hidden in each process. Starts with defining the waste then identifying the cause and their possible solutions and finally control plan.
Causes Identification
Possible cause (Fish-bone Diagram)
Prioritization of cause
Fish-Bone Diagram (Possible causes)
Waste
Materials
Method Person Equipment
Measurement Environment
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause Fish-Bone Diagram Should be constructed for all types of non-value added steps listed out in define phase.
Cause Prioritization Cause Prioritization Matrix
Impact
% Contribution
to waste
-ev effect
on Quality
%
Contributio
n to Cost
Final
Score Weightage 10 10 10
C
a
u
s
e
s
Cause-1 0
Cause-2 0
Cause-3 0
Cause-4 0
Cause-5 0
Cause-6 0
Cause-7 0
Cause-8 0
Cause-9 0
Cause-10 0
Cause Prioritization Matrix should be constructed for every Fish-Bone Diagram constructed. This is done through Brain Storming.
Solution Selection
Possible Solutions Solution Selection
Generate Solutions
Solution Generation
S.No. Valid Causes Possible solutions
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
Selection Process
Solution Selection
S.no. Solution
Easy to
implement
Fast to
implement
Cheap to
implement
Within team’s
control
Easy
reversible
No Side
Effects
1.1
1.2
1.3
1.4
1.5
Answer in yes/no. every yes=1 and every No=0. Acceptability Criteria Depends upon your choice
Solution with 100% score should be implemented without further analysis .
Evaluate generated possible solution for each cause separately
Process evaluation after Improvement
• Calculate the % reduction of non-value adding steps
• Quantify % waste reduction.
• Calculate cost saving done.
• Calculate % increase in productivity.
Control
Control measures are implemented to prevent the occurrence of same errors which are eliminated during improvement over time
Types of Control
• Engineering Control-
• Administrative Control
• Work Practice controls
Engineering control
2. Error Detection and Alarms
1. Guide Pins 3. Limit Switches
4. Counters
Work Practice Control
• Work practice controls are procedures that reduce the likelihood of waste generation by altering the way in which a task is performed.
– E.g. Design the SOP with maximum % of value added steps.
Administrative control
• Giving proper training to the employees.
• Job rotation- helps destroy monotony
• 5S sustenance plan
• Visual control and checklist
• Color Coding
Thank You
References: • Toyota way • http://leanman.hubpages.com/hub/Seven-Wastes • http://yalindanisman.wordpress.com/2012/06/08/
mura-muri-ve-muda/