seven wastes
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Definition of watesTRANSCRIPT
Seven wastes Seven wastes Seven wastes Seven wastes
By K.MARIAPPAN
WASTE
• TOYOTA defines Waste as: "anything other than the minimum amount of equipment, materials,parts, and working time absolutely essential to production."
• The mission of LSPS is to eliminate waste to improve productivity.
• Simply we can remember the Seven Wastes by using the acronym "TIM WOOD"
7 Types of wastes
Transport
Inventory
Motion
Waiting
Over Production
Over Processing
Defects
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KODAK OPERATING SYSTEM
CALL IT CALL IT TWENTY?TWENTY?
…22 TO BE ON …22 TO BE ON THE SAFE SIDE!THE SAFE SIDE!
TEN TEN PLEASE!PLEASE!
Over - Production
Taiichi Ohno’s 7 Wastes
KODAK OPERATING SYSTEM
Waiting
KODAK OPERATING SYSTEM
Transportation
KODAK OPERATING SYSTEM
How do you spell that?
Over -Processing
KODAK OPERATING SYSTEM
Inventory
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KODAK OPERATING SYSTEM
Motion
KODAK OPERATING SYSTEM
Defects / Rejects / Re-work
• Unnecessary Transport of materials
• In moving products between factories, between work
centres, between desks, between machines, all that is
added is lead-time – no value is created.
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
Transport waste :
KODAK OPERATING SYSTEM
Transportation
• Transport Waste is only eliminated through removing its sources.
• In general, these are in fact Inventory Wastes, which due to their pervasive nature, are hard to see or eliminate.
• In general, these are tackled through a slower-burn version of kaizen, often lasting a few months.
• The nature of Transport Waste is such that it often crosses departmental boundaries (following the value stream).
• To eliminate its sources therefore requires cross-departmental teams.
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
KODAK OPERATING SYSTEM
Transportation
KODAK OPERATING SYSTEM
Inventory
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• Inventories beyond the absolute minimum
• Caused by overproduction, inventories take up floor space –
something that is always at a premium in factories and
offices. There's always a dendancy to use inventories to
mask other problems. Remember, if you've got pleanty of
spares, there's no incentive to fix problems with quality!
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
Inventory Waste:
• Significant amounts of Inventory Waste exist in almost all processes.
• These can usually be significantly reduced through a concerted, short-term project.
• In this, a team including those who actually run the process, technical experts, lay-persons, and a facilitator expert plan and implement changes within a week.
• This is often called a “Kaizen Blitz”, or “kaikaku” from the Japanese terms for such shop floor-led improvements.
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
KODAK OPERATING SYSTEM
Motion
• Motions of employees
• Looking for parts, bending / reaching for materials,
searching for tools, etc.
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
Motions waste :
• Waiting for the next process step.
• While waiting, the product is just soaking up ‘overheads’ –
the last thing that the customer actually wants to pay for!
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
Waiting waste :
KODAK OPERATING SYSTEM
Waiting
• Overproduction ahead of demand.
• This exposes the organisation to risks in changing demands
from customers, and is a disincentive to the firm to reduce
the other wastes, since there’s always plenty of extra material
to use in case of problems.
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
Over Production waste :
KODAK OPERATING SYSTEM
CALL IT CALL IT TWENTY?TWENTY?
…22 TO BE ON …22 TO BE ON THE SAFE SIDE!THE SAFE SIDE!
TEN TEN PLEASE!PLEASE!
Over - Production
Taiichi Ohno’s 7 Wastes
• Overprocessing of parts
• Running parts on machines that are too fast / too slow, or
even too accurate to achieve the customer’s definition of
Value. What's the problem with doing too good a job? Well
generally it means too expensive a job for the market's
expectations.
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
Over Processing waste :
KODAK OPERATING SYSTEM
How do you spell that?
Over -Processing
KODAK OPERATING SYSTEM
Defects / Rejects / Re-work
• Producing Defective parts
• If processes produce defects, then extra staff are needed
to inspect, and extra materials needed to take account of
potential losses. Worse than this, INSPECTION DOES NOT
WORK. Eventually you'll miss a problem, and then send a
defective product to a customer. And they WILL notice, at
which point, all hell will break loose!
Transport Inventory Motion WaitingOver prodn
Over processing
Defect
Defect waste :
• When you're trying to figure out if you're looking at Transport Waste, or Inventory Waste, it's useful to remember that there are only three basic reasons for waste being unavoidable.
• The laws of physics. It would be great to speed things up by using magic, but that's sadly not possible!
• The laws of the land. You could reduce machine set-up time by removing all the safety guards, but killing your staff is illegal.
• Outright cost. Got a 20,000 ton press in the wrong location? You're probably going to have to live with that kind of problem
Things to be consider. . . . .
