Professional Documents
Culture Documents
The Seven Waste
The Seven Waste
Waste Elimination
Contents of an Operation
Value Added Work a ue dded o
The part of the job the customer wants to pay for
Obvious Waste
Work that does not add value and is not necessary
WASTE
The7Wastes
Transportation
Defects
Waiting
Overproduction
7 Wastes - Overproduction p
1. Making more t a t e custo e needs a g o e than the customer eeds
Making in large batches Overrunning an unstable process To produce more than is required* To produce before required* * (by internal or external customer)
Overproduction
The 7 Wastes
7 Wastes - Waiting g
2. Man o Machine Waiting a or ac e a t g
Waiting for material Waiting for maintenance Waiting for tool change Waiting for quality check Waiting for next station Waiting for quality checks Non value added work in cycle o a ue o cyc e Operator inactivity during cycle Machine inactivity during cycle
waiting-time
The 7 Wastes
7 Wastes - Transportation p
3 ate a /pa ts o e e t 3. Material/parts movement
Transportation
Unnecessary moving or handling of parts. Handling equipment moving with no parts. Raw material batch sizes not matching production batch size. Material stored a long way from point of use.
The 7 Wastes
7 Wastes - Process
4. Inefficient Process e c e t ocess
Wrong choice of equipment Bad definition of customer's needs Useless operations Excessive movement in process cycle Too frequent inspections Excessive set-up or downtime S o complicated processes Slow co p cated p ocesses Useless refinement Bottlenecks Unbalanced process
Process
The 7 Wastes
7 Wastes - Inventory y
5 a ge Stocks 5. Large Stoc s
Stock pile of finished goods High WIP High raw materials Excessive racking and warehouse space Excessive handling equipment
Inventory
Just In Time
The 7 Wastes
Just In Case
10
Machine breakdown
Inventory Costs !
The7Wastes 11
The 7 Wastes
12
7 Wastes - Defects
7. Less t a Perfect Parts ess than e ect a ts
Scrap Defects Rework Trimming Rejects Recalls Delay due to defects Transportation due to de ects a spo tat o defects Re-inspection and sorting Rework area inside production process Overtime to meet demand due to poor quality
The 7 Wastes
13
Transportation
Defects
Waiting
Overproduction