the eight wastes
Post on 25-May-2015
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Finding Innovation Through Teamwork
The 8The 8Forms ofForms of
WASTEWASTE
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
What is Waste?
• Muda (Japanese word for waste)
• More specifically, any object or activity that adds NO value to the expected outcome
• Value is in the eyes of the CUSTOMER
• Waste absorbs both time and money, causing inefficiency
• 7 forms of waste originally identified by Taiichi Ohno (1912-1990)
Finding Innovation Through Teamwork
Muda, Mura & Muri
Finding Innovation Through Teamwork
The Value Stream
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Over Production
• Making too much
• Producing too early
• Making it “just in case”
• Considered the most serious of the wastes
• Examples?– Making too many copies– Double entering/writing anything– Making widgets early and having them sit on the
production floor.
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Waiting
• When time is not used effectively
• Anytime materials or components are not moving or adding value
• Examples:– Waiting for people– Documents that sit,
waiting for a signature– WIP waiting for the next
step in a process– Late deliveries (supplies)
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Transporting
• Movement of materials within a factory• The number of movements = the number of
opportunities to damage and/or deteriorate• Automate transportation whenever possible• In Japan… AGVs, material delivered to where it is
needed (vehicle dashboards)
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Inappropriate (Over) Processing
• Machines and/or processes that are not capable of quality output
• Using the wrong tool for the job– Cracking a nut with a
sledge hammer– Cutting down trees
with a dull axe
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Unnecessary Inventory
• The “enemy” of quality and productivity
• Inventory exceeding specified quantity limit– Some degree of buffer inventory can be
acceptable when supplier lead times are long and can not be changed.
– Kanban should be implemented, pull
• Negative impact on cash flow
• Think about your office supply room…– Paper and toner
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Unnecessary Motion
• Refers the ergonomics of the workplace• Too much bending, turning, reaching, walking, or
moving to do the job (ie. wrench > air ratchet > quick connect)
• Everything you need to perform a task should be within arms reach and in front of you
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Defects
• Producing something that does not meet the customer’s expectation(s).
• Internal and external failures
• Scrap, rework, less than perfect yield, complaints, missing info, etc…
• Generally, the form of waste that gets the most attention. – Why?
Finding Innovation Through Teamwork
#8 Unused or Misused Skills / Talent
Not taking full advantage of peoples skills, knowledge and abilities…
“But that’s the way we’ve always done it…”
Finding Innovation Through Teamwork
Unused or Misused Skills/Talents
• Not going to the gemba
• Not involving the stakeholders in problem solving and root cause analysis
• Preventing people from reaching their potential by utilizing their abilities
• Product of micromanaging
• Your front-line staff are the ones charged with creating the value for your customers. Therefore, they need to be engaged.
Finding Innovation Through Teamwork
Waste Elimination Tool
Finding Innovation Through Teamwork
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