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4/6/23, 16:32 8 Wastes of Lean Manufacturing | DOWNTIME | TIMWOODS

What are the 8 Wastes of Lean?

→ 8 Wastes of Lean are Transportation, Inventory, Motion, Waiting, Overproduction, Over-
processing, Defects, & Skillset or Non-utilized talent.
The acronym we can say as TIMWOODS or DOWNTIME.

Examples of 8 Lean Wastes:

➨ TIMWOODS

1. T = Transportation
2. I = Inventory
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3. M = Motion
4. W = Waiting
5. O = Overprocessing
6. O = Overproduction
7. D = Defects
8. S = Skill Set Most Popular
➨ DOWNTIME
Problem Solving
1. D = Defects
Methods | Steps, Process
2. O = Overproduction Examples
3. W = Waiting
4. N = Non-utilized Talent 7 QC Tools for Process
Improvement | PDF |
5. T = Transportation Case Study
6. I = Inventory
7. M = Motion Top Lean Tools | Top 26
Lean Manufacturing
8. E = Extra processing
Tools | Examples

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What is Waste in Process or Lean Manufacturing? Categories

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→ In simple language, It is something that adds no values. or 7 QC Tools (8

→ "Our customers would not be happy to pay for any action that we take is called waste" Control Chart (3
→ People usually, only think about all of the scrap material that gets thrown away. They
Difference (9
often forget about all of the other actions that_waste our time, our resources, and our
FMEA (3
money.
→ Would you want to pay for the machine operators wages while : General (1

⇢ They sat idle waiting for a delivery, IATF 16949 (4

⇢ For the rework processes that had to be undertaken because the machine was ISO 9001 (9
incorrectly set or
Lean Manufacturing (1
⇢ Even for storing your product for three months before it was delivered to the store?
→ These all activities are included within the cost of your products, either inflating the price Lean Six Sigma (13

you pay or reducing the profit of the company. Lean Tool (14

MSA (8
How do you get rid of 8 wastes of lean? New 7 QC Tools (9

→ For getting rid of the 8 wastes of lean we have to identify all wastes then find our OEE (3
optimum solution and implement one of the below methods. PPAP (

1. Elimination Problem Solving Method (10

2. Replacement Process Mapping (4
3. Prevention
Quality (5
4. Facilitation
Quality Core Tools (5
5. Detection
Six Sigma (1
6. Mitigation
SPC (3

Terms & Definition (4

Eight Wastes in Lean Manufacturing:
TPM (1
1. Transportation
2. Inventory

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3. Motion
Bolsade Valores:
4. Waiting Curso Gratis
5. Overproduction Ad Mister Market Pro
6. Over-processing Financia sin
7. Defects intereses

8. Skills sets (non-utilized talent) Ad AGN Ingenieros

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Transportation waste: Ad UTP
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→ Transportation_waste in Lean Manufacturing is not adding any value to the product and necesita
it directly impacts your financial indicator and it can be a very high cost to your business,
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you need people to operate it and equipment such as trucks or forklifts to undertake this
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movement of materials. Miraflores
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→ Transportation is the movement of materials from one location to another and it does Ad Lizini Inmobiliaria
not add any value to the product. Pre Venta en Asia
→ Your customer is not willing to pay for that.
→ Transportation adds no value to the product and you are paying people to move Ad Los Portales
material from one location to another so this is not good for the organization. Copy trades from
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Transportation Waste Examples:

→ Sending unsold products from the store to the warehouse back.
→ Ordering parts or products from distant suppliers when closer options are available.
→ Moving parts from one station to another.
→ Moving equipment from one construction site to another.

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Inventory Waste:
→ Every piece of product tied up in raw material, work in progress or finished goods has a
cost and until it is actually sold that cost is yours.
→ Inventory has to be stored, it needs space, it needs packaging and it has to be
transported around.
→ It has the chance of being damaged during transport and becoming obsolete.

Inventory Waste Examples:

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→ Too much Raw material, work in progress (WIP), and too much finish goods (FG).
→ Inventory of extra spares and machines in ideal condition.
→ All inventory should be optimum and minimum.

Motion Waste:
→ Unnecessary movements of man or machine which do not add any value in the product
are known as motion_waste.
→ Excessive machine movements from the machine start point to actual work start point.
→ All of these unnecessary motions cost you time (money) and cause stress on your
employees and machines.

Motion_Waste Examples:
→ Software that requires 10 clicks to start.
→ Workers searching for missing tools or instruments.
→ Excessive travel between workstations.

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Waiting Waste:
→ Waiting for a delivery from a supplier or an engineer to come and fix a machine?
→ We have to spend a huge amount of waiting time for things in our working environment.
→ People and processes often must wait because the next step in the process isn’t ready
for them yet so it is_waste.

Waiting_Waste Examples:
→ Emergency room patients waiting for test results in a hospital.
→ Farmer is waiting for water for the crop and airplane for a gate to open up

Over Production Waste:

→ If we have manufactured any X products and the customer does not want it now that is
called Over Production or if the customer wants product X - 500 Nos and we manufacture
550 in that case 50 extra pieces are Over Production.
→ This is usually because of working with oversize batches, long lead times, poor supplier

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relations and a host of other reasons.

→ Overproduction leads to high levels of inventory which mask many of the problems
within your organization.
→ The aim should be to make only what is required when it is required by the customer, the
philosophy of Just in Time (JIT) or Continuous Flow (Single Piece Flow) however many
companies work on the principle of Just in Case! (JIC).

Over Production_Waste Examples:

→ Production is more than customer demand.
→ Huge meals in restaurants.
→ Hospitals with more beds than the community needs.
→ Overstaffed retail stores

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Over Processing Waste:

→ Over-processing is doing more than the customer wants and give money for the product
or service.
→ Sometimes Over Processing_waste generates due to inappropriate techniques, oversize
equipment, working to tolerances that are too tight, perform processes that are not
required by the customer and so on.
→ All of these things cost us time and money.

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Over Processing_Waste Examples:

→ If Microsoft Excel is enough for us and we go for mini-tab for calculation.
→ Another example: X-ray is sufficient and we go for an MRI.
→ If the lathe machine is sufficient for operation and we are doing the operation with the
CNC machine.
→ Complex purchasing processes with multiple approval levels.
→ One of the best examples for over processing is before sending mail to the manager we
read twice or thrice.

Defects Waste:
→ Defects hide many other problems and wastes.
→ Quality errors that cause defects invariably cost you far more than you expect.
→ Every defective item requires rework or replacement, it wastes resources and materials, it
can lead to lost customers.
→ We have to work on defect prevention instead of defect detection.
→ Implementation of Poka-Yoke systems and automation can help to prevent defects from

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occurring.
→ We can use Jidoka/Autonomation for defect prevention purposes.
→ We also implement standard operations procedures (SOP) and training to ensure that
the correct methods are undertaken and standards achieved.
→ The defect is directly related to the Cost of Poor Quality.

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Defects Waste Examples:

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→ Software with bugs is a defect that has to be re-coded.

→ Misdiagnoses in healthcare that lead to unnecessary tests or treatment.
→ Products that are shipped to the wrong address is also a defect.
→ Manufactured items that don’t meet the customer’s specifications is a defect.

Skill-Set (non-utilized talent) Waste:

→ Skill-set or non-utilized talent is newly added_waste in Lean and it costs you money.
→ Not fully utilized people represents the_waste of talent present in many organizations.
→ Because operators are close to their processes daily, they can often recognize problems
or opportunities that staff or superiors just don’t see, but the workers may never be asked
for their input.
→ They may also have outside talents that aren’t formally part of their assigned jobs but
could be of use.
→ The recommendation? Value people for their brains, not just their brawn.

Skill-Set (non-utilized talent) Waste Examples:

→ Intentionally we are not including any competent employee or any department or
section is also an example of non-utilized talent.
→ If we do not give our workers any chance for process improvement or any suggestion
about improvement is also comes under skillset_waste.

The Benefit of Elimination of Wastes:

→ It Improves efficiency and effectiveness
→ Increase the productivity of production processes
→ It will increase the performance of plant indicator OEE (Overall Equipment Effectiveness)
→ It creates a safer working environment for all employees.

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→ Reduce downtime

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18 Comments

John Mulindi April 30, 2021 at 6:40 PM

I didn't know we have these many types of wastes in manufacturing. So much to learn from
your post. Thanks for sharing.

Reply


Nikunj Bhoraniya  May 3, 2021 at 11:03 PM

John Mulindi very much thank you

Hassan Suliman October 21, 2021 at 4:34 PM

Very informative, thank you so much

Reply


Nikunj Bhoraniya  November 13, 2021 at 9:05 PM

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4/6/23, 16:32 8 Wastes of Lean Manufacturing | DOWNTIME | TIMWOODS

Thank you for your valuable feedback!!

Unknown November 13, 2021 at 6:57 PM

Thanks for all this detail. Ver well explained it is a benefit to all looking to eliminating waste
in their process..

Reply


Nikunj Bhoraniya  November 13, 2021 at 9:06 PM

Thank you

Unknown February 23, 2022 at 4:11 PM

Pictorial representation helps to understand content

Reply


Nikunj Bhoraniya  March 22, 2022 at 6:55 AM

Thank you for your valuable feedback

‫الخير‬ March 23, 2022 at 5:38 PM

Thank you

Reply


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
Nikunj Bhoraniya  July 10, 2022 at 12:40 PM

You are Most Welcome

Anonymous June 26, 2022 at 10:50 AM

Well explained

Reply


Nikunj Bhoraniya  July 10, 2022 at 12:39 PM

Thank you for your valuable feedback

GANESH RAJ July 19, 2022 at 6:05 AM

Very Informative and I am learning many new things from your posts. Thank You very much
for sharing. Appreciate your willingness to share.

Reply


Nikunj Bhoraniya  September 20, 2022 at 11:27 AM

You are most welcome and happy learning

Anonymous August 2, 2022 at 8:20 AM

Worthy Group

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Reply

Nikunj Bhoraniya  September 20, 2022 at 11:28 AM

Thanks and happy learning!!!

Anonymous November 4, 2022 at 1:44 PM

Thank you! Very comprehensive & simple but my advise is to add more examples from
manufacturing & factories since I noticed many examples such as for overprocess, related
to IT & software despite of there are huge no. of examples in the manufacturing industry.
My opinion only 😊

Reply


Nikunj Bhoraniya  November 21, 2022 at 9:10 PM

Thanks for your opinion we will definitely add more examples form manufacturing
industry

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