www.mapbizsolutions.com

Identifying Waste Within Your OrganizationType Definition Manufacturing Examples Office/Administrative Examples Suggestions

Waiting The item/work hasstopped.

Machine Downtime Bottlenecked

Operations Equip. Changeover

System Downtime System Response Time Approvals from Others Information from Customers

Improve equipment reliability through TPM. Shrink changeover through SMED. Push decision making down to lower levels. Make it easy for customers to provide information Cross-train employees so that work can continue when someone is

absent. Make sure all supplies are available.

Transportation Movement of workor paperwork fromone step to the nextstep in the process.

Move materials, parts,or finished goods intoand out of storage

Movement of documents fromsite to site, office to office

Make the distance over which something is moved as short as possible. Consider work cells and co-located teams.

Overprocessing Having to doanything more than

is needed.

Taking unneeded stepsto process the parts

Inefficient processingdue to poor tool andproduct design

Re-entering data Extra copies Unnecessary or excessive reports

Remove unnecessary steps. Use design for manufacturability. Stop copying everyone on emails. Stop sending reports and see who complains. Stop unnecessary signoffs and reviews.

Inventory Any supply that isin excess.

Any excess inventory Batch processing

Office supplies Sales literature Batch processing transactions

Produce only enough to satisfy your downstream customer. Ensure that work arrives at the downstream process when it is

required. Create print on demand processes for reports and documents.

Defects Any form of scrap,mistakes, errors, or

corrections.

Production ofdefective parts

Scrap Waste

Data input errors Design errors Engineering change orders Invoice errors

Error-proof steps. Used standardized work instructions. Post job aids. Checklists.

Motion Movement ofpeople

Reaching Looking Stacking

Walking to/from copier Central filing Fax machine

Arrange work areas to shrink movement. Consider cell type manufacturing. Part trays located close to the worker. Provide extra fax and copy machines. Locate files at work stations. Standardize folders, drawers, and cabinets throughout the work area

(5S).Overproducing Producing more,

sooner, or fasterthan is required by

the next person.

Inventory piling up ata slower downstreamstep

Printing paperwork before it isreally needed.

Purchasing items before they areneeded.

Processing paperwork before thenext person is ready for it.

Establish a flow sequence to satisfy the downstream customer. Create workplace guidelines and standards for each process. Create signal devices to prevent over processing, e.g. FIFO lanes.

Underutilizedpeople

People’s creativity,ideas, and abilities

are not fully tapped.

Losing ideas, skills,and improvements bynot listening toemployees

Limited employee authority andresponsibility for basic tasks.

Management command andcontrol

Institute Quality Circles. Institute Employee Suggestion Systems. Form worker teams to solve process problems (Kaizen Events)