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Lean-Insight.comLean Six Sigma Training

Part 8

Training Centers: Bangalore, Chennai and Hyderabad

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Waiting Cont.

Symptoms: People waiting on systems (e.g.

copier) People waiting on others

Sign offs Edit Client input Compliance / legal

Lack of information to complete a process

Delay in the upstream process step

Causes: Inconsistent work methods Poor process/person effectiveness Inefficient process Inappropriate metrics Lack of training

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7. Transportation

Information Generated

Entered

Filed

Sent to the Plant

Verified

Filed

Approved

Entered

Returned

Excess movement of what flows in the process. This can be the product material or documents.

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8. Intellect/ Unutilized skills

Symptoms: Few improvements 99.9% is good enough Doing MY job mentality Lack of employee involvement Lack of team activities Poor morale

Causes: Blame the person, not the process

(focusing on who made the error, not why the error occurred)

Hide the problems Status quo never challenged Poor suggestion program Lack of accountability

Definition:Any failure to utilize the

time and talents of the people

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Overproduction

Inventory

Extra Processing

Motion

Defects

Waiting

Transportation

•Processing before next operation is ready•Processing prior to need•Making decisions too early

• Multiple credit applications awaiting approval• Unnecessary document / data storage

• Navigating multiple screens to input data• Multiple ways to do the same task• Printed material• Duplicate entries• Navigating multiple screens to input data• Printing Material• Ergo…walking, bending, twisting• Looking for data / info• Personal data incorrect• Missed customer due dates• Data entry errors• Rework• Credit applications awaiting approval• Info awaiting an overnight “systems batch run”• Manual decisions• System downtime / response time

• Delivering hard-copies• Shipping hard-copies requiring signature

•Sub assemblies and components between feeder & main lines

•Material between operations & process steps• Inventory stored in warehouses•Buffer & safety stock inventory

• Planned re-work• Un planned re-work• Handwork…polishing, deburring

•Operators bending, turning, twisting, reaching, walking•Machines “cutting air”•Robotic motion “getting back to home”• Poor quality of materials• Equipment failures• Missing customer due dates…internal & external•Operators waiting•Machines waiting •Customers waiting

•Conveyance of any materials, tooling•Conveyance systems

What is Waste?…Examples

8 Wastes Product Flow Knowledge Flow

Unutilized Skills: Any failure to utilize the time and talents of the people

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Find examples of the 8 Wastes in your operation

Motion

Transportation

Over Production

Inventory

Waiting

Processing

Correction

Waste Scavenger Hunt

Unutilized skills

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Lead Time

Value Added

Non-Value Added

Non-Value added activity increases lead times, adds cost, creates opportunities for defects, increases inventories, and inhibits Flow Production.

Value Added vs Non-Value Added

Start End

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New Lead Time

Lean tools help us identify and eliminate waste from our processes, leading to: Reduced costs Reduced lead time Faster response Improved quality Reduced inventory Reduced floor space Better predictability

Lead TimeWaste Waste

Compress the time

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If you are looking for Lean Six Sigma training along with certification in Bangalore visit: http://lean-insight.com/six-sigma-training-bangalore/