What is Waste?

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Lean Production System
The toolbox for all lean activities

Elimination of all Waste

Cost and Market Leadership

Level 1 – Enabler Level 2 – Basics Level 3 – Experts Level 4 – Pro-Tools

Total
Obeyaka / Inbound Mizusumashi / Safety / Heijunka /
Standardization Lean Training Productive
Lean Layout Milkrun Tow Train Ergonomics Leveling
Maintenance

Takt Time / Operator-

One Piece Yamazumi / Mixed Model
5S Zero Buffer Process Supermarket
Lead Time Flow Line Balancing Line
Flexibility

3P /
Small-sized SMED 2-Box Jidoka /
Visualization Andon Pull / Kanban Design for
Packaging Changeover Principle Hanedashi
Manufacturing

Create a Vision
Lean Self-Assessment / Value-Stream-Design (VSD) *) derived from the “Toyota
Production House”

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1. Overproduction

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 2. Inventory

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3. Transport

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 4. Movement

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 5. Waiting

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 6. Defects

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7. Over-Engineering

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 The Seven Types of Waste

Over Production Inventory Transport Movement

Waiting Defects Over-Engineering

Important takeaway
All lean activities aim on the target to permanently reduce waste in a business. Waste occurs in different variations and may be
visible or not. The seven types of waste are defined as the causes for inefficiency.

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 The Seven Types of Waste
(Examples)

Over Production Inventory

 Non-synchronized processes  Raw material, semi-finished goods
 Fixed capital  Fixed capital
 Quality loops  Quality loops
 Floor space  Floor space

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 The Seven Types of Waste
(Examples)

Transportation Movement
 Double handling  No value adding
 Long distance  Could have been avoided by design
 Handlings device

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 The Seven Types of Waste
(Examples)

Waiting Defects
 Waiting for material  Double check
 Wairing for men  Double handling
 Waiting for machine  Scrap & Rework

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 The Seven Types of Waste
(Examples)

Over-Engineering
 Technology does not fit requirements
 No value adding

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