elements of waaste

7/29/2019 Elements of waaste

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Seven Components of Waste

Muda is classified into seven components:

– Overproduction

– Correction (defects)

– Inventory

– Motion

– Overprocessing

– Conveyance

– Waiting

Sometimes additional forms of muda are added:

– Under use of talent

– Lack of safety

Being Lean means eliminating waste.



Overproduction

Overproduction is producing more than the next step needs ormore than the customer buys.

– It may be the worst form of waste because it contributes to all the

others.

Examples are:

Preparing extra reports

Reports not acted upon or even read

Multiple copies in data storage

Over-ordering materials

Duplication of effort/reports

Waste of Overproduction relates to the

excessive accumulation of work-in-process

(WIP) or finished goods inventory.



Correction

Correction or defects are as obvious as they sound.

Examples are:

Incorrect data entry

Paying the wrong vendor

Misspelled words incommunications

Making bad product

Materials or labordiscarded during

production

Waste of Correction includes the waste of handling

and fixing mistakes. This is common in both

manufacturing and transactional settings.



Inventory

Inventory is the liability of materials that are bought, investedin and not immediately sold or used.

Examples are:

Transactions notprocessed

Bigger “in box” than “out

box”

Over-ordering materialsconsumed in-house

Over-ordering raw

materials – just in case

Waste of Inventory is identical to overproduction

except that it refers to the waste of acquiring raw

material before the exact moment that it is needed.



Motion

Motion is the unnecessary movement of people andequipment.

– This includes looking for things like documents or parts as well asmovement that is straining.

Examples are:

Extra steps

Extra data entry

Having to look forsomething

Waste of Motion examines how people move to

ensure that value is added.



Overprocessing

Overprocessing is tasks, activities and materials that don’t

add value.

– Can be caused by poor product or tool design as well as from not

understanding what the customer wants.

Examples are:

Sign-offs

Reports that contain moreinformation than thecustomer wants or needs

Communications, reports,emails, contracts, etc that

contain more than thenecessary points (briefer isbetter)

Voice mails that are toolong

Waste of Overprocessing relates to over-

processing anything that may not be adding

value in the eyes of the customer.



Conveyance

Conveyance is the unnecessary movement of material andgoods.

– Steps in a process should be located close to each other somovement is minimized.

Examples are:

Extra steps in the process

Distance traveled

Moving paper from placeto place

Waste of Conveyance is the movement of material.



Waiting

Waiting is nonproductive time due to lack of material, people,or equipment.

– Can be due to slow or broken machines, material not arriving ontime, etc.

Examples are:

Processing once eachmonth instead of as the

work comes in

Showing up on time for ameeting that starts late

Delayed work due to lack

of communication fromanother internal group

Waste of Waiting is the cost of an idle resource.



Exercise

Exercise objective: To identify waste that occurs in

your processes.

Write an example of each type of muda below:

– Overproduction ___________________

– Correction ___________________

– Inventory ___________________ – Motion ___________________

– Overprocessing ___________________

– Conveyance ___________________

– Waiting ___________________



5S – The Basics

5S is a process designed to organize the workplace, keep itneat and clean, maintain standardized conditions and instill

the discipline required to enable each individual to achieveand maintain a world class work environment.

• Seiri - Put things in order

• Seiton - Proper Arrangement

• Seiso – Clean

• Seiketsu – Purity• Shitsuke - Commitment



English Translation

There have been many attempts to force five English “S” words to maintain

the original intent of 5S from Japanese. Listed below are typical English

words used to translate:1.) Sort (Seiri)

2.) Straighten or Systematically Arrange (Seiton)

3.) Shine or Spic and Span (Seiso)

4.) Standardize (Seiketsu)

5.) Sustain or Self-Discipline (Shitsuke)

5 S

SortIdentify necessary items and

remove unnecessary ones, use

time management.

ShineVisual sweep of areas,eliminate dirt, dust and

scrap. Make workplaceshine.

Place things in such away that they can be

easily reached wheneverthey are needed.

Straighten

Make 5S strong inhabit. Make problems

appear and solve them.

Self-DisciplineStandardize

Work to standards,maintain standards, wear

safety equipment.



Exercise

Exercise objective: : To identify elements of 5S in your

workplace.

Write an example for each of the 5S’s below:

• Sort ____________________

• Straighten ____________________

• Shine ____________________

• Standardize ____________________

• Self-Discipline ____________________



Summary

At this point, you should be able to:

• Describe 5S

• Identify and describe the 7 Elements of Waste

• Provide examples of how Lean Principles can affect your area



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