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Waste

Waste Elimination

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Contents of an Operation

Value Added Work

The part of the job the customer wants to pay for

Non Value Added or Hidden Waste

Work that does not add value but is necessary under thecurren opera ng con ons

Work that does not add value and is not necessary

WASTE

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What is Value Added Work?

Work that increases the value of a part..e. a w c c anges e , orm or unc on

o geroll

e.g. p essbend

heat treatl

drillf rm

glue

assemble

weld

paint.polish

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What is Hidden Waste?

Work that does not add value but is necessar

tool chan eover

under the current operating conditions.

inspection

arts handlin

unavoidable transportation parts

unwra in of urchased arts

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What is Obvious Waste?

Work that does not add value Inventory Operator movements

1. Overproduction

.Transportation

2. Waiting

3. Transportation

Process Defects

4. Process5. Inventory

Waiting

6. Operator Movements

7. Defects

Overproduction

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77Wastes - Overproduction

1. Makin more than the customer needs

Making in large batches

Overrunning an unstable process

To produce more than is required*

To produce before required*

Overproduction

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77Wastes - Waiting

2. Man or Machine Waitin

Waiting for material

Waiting for maintenance waiting-time

Waiting for tool change

Waiting for quality check

Waiting for quality checks

Non value added work in c cle

Operator inactivity during cycle

Machine inactivity during cycle

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77Wastes - Transportation

3. Material/ arts movement Trans ortation

Unnecessary moving or handling of parts.

Handling equipment moving with no parts.

Raw material batch sizes not matching production batch size.

Material stored a long way from point of use.

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77Wastes - Process

4. Inefficient Process

Wrong choice of equipment

Bad definition of customer's needs Process Useless operations

Excessive movement in process cycle

Excessive set-up or downtime

Slow com licated rocesses

Useless refinement

Bottlenecks Unbalanced process

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77Wastes - Inventory

5. Lar e Stocks

Stock pile of finished goods

High WIP

Inventory

High raw materials

Excessive racking and warehouse space

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Types of Waste - Inventory

Inventory conceals problems, makes control difficult and

Delays action in dealing with faultsand defects

o scures t e opportun ty or mprovement.

Eliminate rocks

Reduces need to face up to fast toolchangeovers

= solve problems

= eliminate waste

capability Goods can become damaged or

Creates unnecessary searching and

movement of materials

Machinebreakdown

Supplier

deliveryLongtravelling

Conceals excess personnel

Takes up space

par s

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77 Wastes - Operator Movements

6. Useless motion

Looking for tools, materials etc

Double handling Operator movements

Turning

Bending

Walking

etc

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77Wastes - Defects

7. Less than Perfect Parts

Scrap

ReworkDefects

Trimming

Rejects

Delay due to defects

Trans ortation due to defects

Re-inspection and sorting

Rework area inside production process Overtime to meet demand due to poor quality

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What is Obvious Waste?

Work that does not add value Inventory Operator movements

1. Overproduction

.Transportation

2. Waiting

3. Transportation

Process Defects

4. Process5. Inventory

Waiting

6. Operator Movements

7. Defects

Overproduction

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