Seven Wastes

Seven Seven wastes 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

Motion

Over -Processing

Taiichi Ohno’s 7 Wastes

Over - Production TEN PLEASE!

How do you spell that?

CALL IT TWENTY? …22 TO BE ON THE SAFE SIDE!

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Defects / Rejects / Re-work KODAK OPERATING S YSTEM

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Inventory

Waiting $

Transportation

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Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

Transport waste :

• 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.

Tra

Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

• 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 crossdepartmental teams.

Tra

Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

Inventory Waste: • 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 Inventory

spares, there's no incentive to fix problems with quality!

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Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

• 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.

Defect

Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

Motions waste :

• Motions of employees • Looking for parts, bending / reaching for materials, searching for tools, etc.

Motion

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Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

Waiting 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!

Waiting

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Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

Over Production waste :

• 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 Taiichi Ohno’s 7 Wastes

to use in case of problems.

Over - Production TEN PLEASE!

CALL IT TWENTY? …22 TO BE ON THE SAFE SIDE!

KODAK OPERATING SYS TEM

Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

Over Processing waste :

• 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

Over -Processing

expectations.

How do you spell that?

KODAK OPERATING SY STEM

Transport Inventory

Motion

Waiting

Over prodn

Over proce ssing

Defect

Defect waste : • 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!

Defects / Rejects / Re-work

KODAK OPERATING SY STEM

Things to be consider. . . . .

• 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