MUDA- The 7 wastes

Waste 1: Over production

• Produce more than what the customer wants
– Just in case
– Inventory build up
– Take the focus away from the customer
– Affects the smooth flow of goods and products
• Causes
– MRP push rather than Kanban pull
– Looks busy
– Poor people utilisation
 Waste 1: Over production
• Effects
– Costs money
– Consumes the resource ahead of the plan
– Creates inventory
– Hides inventory problems
– Poor space utilisation
 Waste 2: Inventory
• Build up of unnecessary inventory
– Unbalanced production schedule
– Inaccurate forecasting
– Excessive down time/ set up time
– Push instead of pull
– Large batch size
– Unreliable suppliers
 Waste 2: Inventory
• Effects
– Adds cost
– Extra storage
– Extra management resources
– Hides shortages and defects
– Can become damaged/ obsolete
 Waste 3: Motion
• More than what is required movement of
Man for completing a process
– No standard operating procedure
– Poor house keeping
– Badly designed work place
– Inadequate training
 Waste 3: Motion
• Effects
– Interrupts production flow
– Increases production time
– Can cause injuries
 Waste 4: Waiting
• People or Equipment waiting for parts or
materials
– Bottlenecks in the process
– Machine availability
– Shortages and unreliable supply chain
– Lack of multi skilling/ flexibility
– Breakdowns
– Ineffective production planning
– Quality, design and engg issues
 Waste 4: Waiting
• Effects
– Stop/start production
– Poor workflow continuity
– Causes bottlenecks
– Long lead times
– Failed delivery dates
 Waste 5: Transportation
• Unnecessary movement of parts between
the processes
– Badly designed process/cell
– Complex material flows
– Sharing of equipment
 Waste 5: Transportation
• Effects
– Wasted floor space and other resources
– Unnecessary material handling
– Potential damage to products
– Increases production time
– Poor communication
– Damage to the products
– Increases WIP
 Waste 6: Over processing
• Going beyond the requirement of the
customer
– Always done it
– Not understanding the process
– Resistance to change
– Out of date standards
– Lack of motivation
– Lack of standard operating procedures
 Waste 6: Over processing
• Effects
– Unnecessary resource consumption
– Increased production time
– Reduces life of the component
 Waste 7: Not right the first time
• Defective product leading to rejection by the
customer
– Out of control / incapable processes
– Lack of skill, training and on the job support
– Inaccurate design and Engg
– Machine inaccuracy
 Waste 7: Not right the first time
• Effects
– Customer dissatisfaction
– Adds to the costs due to rectification
– Schedules are interrupted
– Creates paper work
 Waste 8
• Under utilisation of people
 Managing Waste
• Identify the waste and quantify
• Prioritize
• For each waste develop strategies to reduce
the waste
• Implement and monitor
 MURI
• Overburden on the employees affecting the
morale
• Too many tasks and decisions to be taken
which he can not manage
– Standardization of jobs
– Identify the normal and abnormal tasks
– Task time and contents are well defined
 MURA
• Unevenness in production related to manpower
or materials
• Uniform workload to be provided for increase in
productivity
• Tasks to be divided into normal and abnormal
tasks which can be easily distributed and
managed
• Jobs to be completed per day can be planned
and completed