the seven deadly wastes course objectives learn what the seven deadly wastes are and how they affect...
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The Seven Deadly WastesCourse Objectives Learn what the Seven Deadly Wastes
are and how they affect our business. Identify the Waste in our business and
develop an action plan to eliminate it. Develop an action plan to teach others
what the Seven Deadly Wastes are and how to eliminate them.
First – The History Lesson Have you heard of Mass Production?
This method of production was brought to the forefront with Henry Ford’s invention of the automobile.
Lean
Manufacturing Mass Production
Skilled Craftsmanship
1900’s 1930’s 1960’s TODAY
Dr. Deming Enters the Scene
Following WWII, the lean manufacturing approach was developed by American Dr. Edward Deming, to assist the Japanese economy in rebuilding from the impacts of war. The scarcity of raw materials provided the basic premise for lean manufacturing, i.e., use what is on hand in the most efficient manner.
Great Cars from Japan?
How were the first cars from Japan viewed?
How are cars from Japan viewed today?
Welcome the age of Lean Manufacturing.
The Toyota Production System In the early 1960’s TPS was
pioneered by Taiichi Ohno to reflect the philosophies of waste elimination and time management
Highly skilled “work cell” jobs Emphasis on quality and efficiency
TPS Top Three
1. The team must embrace a philosophy of having zero tolerance for waste
2. Activity on a daily basis is focused on creating a stable production environment.
3. Systems are set up to create customer “Pull” or Just-in-Time Delivery
Zero Tolerance For Waste
All unnecessary waste can be eliminated
Stated simply, the goal is perfection
Stable Production Environment
The highest quality product can only be achieved in a stable environment. Problems are instabilities that must be surfaced quickly and solved permanently
Standardization, consistency and predictability and repeatability are the goals. Improve from there!
Customer Pull/JIT Delivery A product should only be built to
meet customers demands. Build only what the customer wants, deliver it when it is expected and with perfect quality
This approach results in the best use of the company’s resources, which leads to greater profitability
Let’s get into the Waste
What are you willing to pay for? Dough, Sauce, Toppings, Toppings dropped
on the floor, Labor cost for delivery driver, Labor cost for delivery driver to stop at girlfriend’s house on the way?
What are our customer’s willing to pay for?
VALUE ADDED ACTIVITY
Value Added Activity
Value is added to a product when it changes the fundamental nature of the product.
Examples: Stamping a bracket out of a coil of
steel
All other activities are non-value added or waste
And here they are . . .
1. Overproduction2. Inventory3. Transportation4. Waiting5. Motion6. Over Processing7. Correction or
Rework
W A S T E
Overproduction
Overproduction is making more of something than the customer requested
Examples:
Running a machine for 16 hours when only 10 are required
Making 2 day’s worth of product when only 1 day’s worth is required
Inventory
Inventory waste occurs when there is more product on hand than the customer requested.
Examples:
More raw material than needed for smooth production
More work-in-process
Transportation
Transportation waste is moving the product more than is necessary
Examples:
Having three storage locations for the same material
Moving raw materials to an offsite warehouse
WaitingAnytime value cannot be added
because of a delay is defined as the waste of waiting
Examples:
Waiting for material Waiting for a machine to be fixed Unbalanced assembly sequence
MotionThe waste of motion refers to any extra
movement of the operator when they are performing the work sequence (excessive or repetitive motion also increases ergonomic issues)
Examples:
Walking 10 feet to retrieve a part or tool
Twisting around to grab a part in the back of the workstation
Overprocessing
Over processing is doing more to the product than the customer requested
Examples:
Plating a product for four hours when only two are required
Testing a product three times when the specification calls for one test
Correction/ReworkAnything that is not “done right the first time”
and requires rework inspection or touchup(Also includes scrap and appearance issues )
Examples:
Re-torquing a bolt Sorting incoming materials Checking a key dimension Trimming thread or flash from a
component
Waste in my cell!!
Waiting
• • •
Inventory
• • •
Motion
• • •
Transportation
• •
Overproduction
• • •
Over Processing
• • •
Correction
• • •
Action Plan for Eliminating Waste and Teaching Others
1. 2. 3. 4. 5. Discuss this with my coach.