Professional Documents
Culture Documents
Input (Resources)
Transformation
Output
Products Services
Purpose of Waste
Educate supplier of the evils of waste
What Where Why Steps to reduce and/or eliminate
Show improvement potential that exists Improve the processs value added content
Identification of Waste
Input
(Resources)
Transformation
Output
Products Services
Defining Waste
Webster: to consume carelessly squander fail to take advantage uncultivated area junk worthless residue loss energy grow weaker
Definition of Waste
Anything that doesnt add value to the process Anything that doesnt help create conformance to the customers specifications Anything your customer would be unwilling to pay you to do
Understanding Waste
Identification and elimination of waste is the central focus of a lean system It is dependent on the understanding and involvement of all employees. Successful implementation requires all employees to be trained to identify and eliminate waste from their work areas
Understanding Waste
Understanding Waste
Waste: Anything other than the minimum resources
Equipment and tooling Direct and indirect labor Material Floor space Energy
Identification of Waste
Types of Waste:
Inventory Overproduction Correction Materials and information movement Processing Waiting Motion
Waste of Inventory
Definition: Any supply in excess of customer requirements necessary to produce goods or services just-in-time
Symptoms Complex tracking systems Extra storage and handling Extra rework/hidden problems Paperwork/documents Stagnated information flow High disposal costs Obsolete material / landfill In-process packaging High utility costs
Root Causes Product complexity Incapable processes Unleveled scheduling Poor market forecast Unbalanced workload Unreliable supplier shipments Inadequate measurement Misunderstood communications Reward system
Working Capital = Cash + Inventory + Accounts Receivables Accounts Payables - collect faster - defer payments - reduce inventory
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WASTE of Overproduction
Definition: Producing more than needed Producing faster than needed Root Causes: Just-in-case logic Misuse of automation Long process set-up Unleveled scheduling Unbalanced workload Over engineered equipment/capability Redundant inspections Lack of reuse and recycling Symptoms Excessive raw materials Extra inventory Unnecessary work Excessive floor space utilized Unbalanced material flow Backups between departments Complex information management Disposal charges Extra waste handling and treatment High utility costs
WASTE of Correction
Definition: Any supply in excess of customer requirements necessary to produce goods or services just-in-time Root Causes: Weak process control Questionable quality Lack of error proofing Unbalanced inventory level Deficient planned maintenance Poor product design Customer needs not understood Improper handling Poorly managed waste streams Inadequate training Symptoms Rework, repairs and scrap Added inventory costs Customer returns Loss of customer confidence Loss of business Missed shipments / deliveries Hazardous waste generation
WASTE of Processing
Definition: Effort which adds no value to the product or service from the customers perspective. Root Causes: Product changes without process changes Just-in-case logic Lack of communication Redundant approvals Extra copies, excess information Undefined customer requirements stop-gap measures that become part of the process Lack of reuse / recycling Symptoms Unnecessary work Extra equipment Longer lead time Reduced productivity Extra material movement Sorting, testing, inspection Inappropriate use of resources Excess energy consumption Processing by-products
WASTE of Waiting
Definition: Idle time created when people wait for machines, people wait for people, machines wait for people, and machines waiting on machines Root Causes: Unbalanced workload Unplanned maintenance Long process set-up times Misuse of automation Quality problems Unleveled scheduling Ineffective layout Specialization Symptoms Under-utilization of resources Reduced productivity Increased in investment Idle equipment Large waiting / storage rooms Equipment running, not producing Unnecessary testing
WASTE of Motion
Definition: Any movement of people or machines Root Causes: Poor ergonomics / layout Machine / process design Inconsistent work methods Poor workplace organization and housekeeping Extra busy movements while waiting Symptoms Reduced productivity Large reach / walk distances Longer lead times Excess handling Reduced quality People / machines waiting High energy cost Inappropriate use of resources
Water
transportation
Non-hazardous waste
Environmental Management