Wastes

7 at one blow

Definition

Any human activity which absorbs resources but creates no value

Muda

Magnificent Seven

Transporting Inventory Motions Waiting Overproduction Overprocessing Defects

Transporting

Moving materials between work stations, buildings, desks, machines

No value added

Inventory

Caused by overproduction Take up floor space Use up cash Do not add value Hide problems

Motions

Of employees

Effort & time that can be eliminated

Does not add value

Waiting

Next process step

WIP

Overproduction

Inventories

Obsolete parts

Overprocessing

Of Parts

Sledge hammer to crack nuts

Defects

Adds a layer of non value added work

Inspection does not work

TIM WOOD

Transport Inventory Motions Waiting Overproduction Overprocessing Defects

Types of Waste

Type one

Type two

Type 1

Determine Utilization and Performance Metrics

Develop a Demand Management Process

Type 2

Kaizen

Shop floor led improvements

Continually Improve

Reasons for Waste

Laws of Physics

Laws of the Land

Outright cost

Reducing 7 Wastes

All that remains—Value stream

Switch production from one product to another

SMED (Single Minute Exchange of DIES)

Reducing 7 Wastes

Three techniques

Minimize forecasting Kaizen projects Remove the source

Level Scheduled

Small batches

Rapid response

Improve Flexibility

Kaizen

Continuous Improvement by those that perform actual work

Perfection is the goal

Employee driven

Remove Waste at its Source

Quality at its source

Fool proofing eliminates the source

Waste Elimination Results

Eliminate All Non-Value Added Activity

Customer pays only for the value they deem valuable

Cost reduced—profits increased