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