The Seven Forms of Waste

Continuous Improvement focuses on the

identification and elimination of the 7 forms of
waste:
 Overproduction
 Inventory
 Unnecessary Motion
 Transportation
 Waiting
 Over Processing
 Defects / Repair / Rework

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1. Over Production

Producing products or materials before they are needed.

Overproduction is the worst form of waste because it is the root

cause of many other wastes.
Results of Over Production:
• Products being produced in excess quantities
• Products being made before customers need them
• Excess Inventory
• Excess Transportation
• Hides available capacity

Caused by:
• Working ahead of customer (internal/external) or process requirements

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Waste Of Overproduction : Example

OPERATOR SHOULD BE IN
THIS STATION (ST 16) BUT IS
WORKING AHEAD IN ST 15

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2. Inventory
Excess inventory is not directly required for current customer
orders.
Results of Excess Inventory:
• requires space
• costs money and ties up capital
• search and transport damage
• hides defects
• excess WIP and finished out-of-date product
• Increased deterioration

Caused by:
• Working ahead of build requirements
• High WIP standards
• No WIP standards
• Lack of JIT/Pull system

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Excess Inventory: Example

STANDARD SET AT 4 HIGH X 3 DEEP PART BIN

STACKED 6 HIGH

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3. Motion

Unnecessary movement in a process.

Some Results of Motion:
• unnecessary walking
• poor ergonomic conditions
• part transfer
• reaching and stopping and walking to locate/ pick up parts/tools

Caused by:
• poor parts placement
• poor process flow
• poor work station layout

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Waste of Motion: Example

TEAM MEMBER IN PAINT SHOP ATTEMPTING TO

UNTANGLE HOSES TO THE BACK-UP GUNS IN
THE TOP COAT BOOTH.

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4. Transportation

The unnecessary movement of materials

Results of Transportation:
• Loss of traceability
• Damaged goods
• Increased Lead Time
• Excess Costs
• Storage space

Caused by:
• Poor parts storage
• Poor Work area layouts
• Working ahead of build requirements
• Lack of JIT/ Pull system

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Waste of Transportation: Example

BODY SHOP CONVEYANCE BODY SHOP T/M CARRIES

DELIVERS AMS BRACKETS TO PARTS TO RACK LINESIDE.
TABLE ON THE FLOOR

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5. Waiting
Periods of inactivity in a downstream process that occur because
an upstream activity does not deliver on time.
Results of Waiting:
• Over Production
• Over Processing
• Idle resources
• Non-Value added work

Caused by:
• Line stops
• Waiting for Material
• Repair/Maintenance
• Waiting for equipment to process
• Missing tools
• Non- “Full” work process

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Waste of Waiting: Example

TEAM MEMBER WAITING ON BODY

IN ST. 3900. ROBOTS IN ST. 2400
WENT DOWN CAUSING DOWNTIME

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6. Over Processing

Producing more or better than the customer requires.

Results of Over Processing:
• Increased Processing Time
• Costs
• Incorrect process/equipment

Caused by:
• Refining the product in ways or areas not
important to the customer
• Wait Time
• Unclear Quality Standards

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Waste of Over Processing: Example

BODY SHOP T/M SANDING

DOOR THAT HAD NO DEFECTS

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7. Defects/Repair/Rework
Products or aspects of the production processes that do not
conform to specifications or to the customer’s expectations.
Results of Defects/Repair/Rework:
• Customer Dissatisfaction
• Non-Value added work
• Extra costs
• Extra space
• Extra inspections/checks

Caused by:
• Scrapped parts
• Wrong or defective tools or machines
• Wrong or missing processes
• Poor Problem Solving
• Unclear Standards

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Waste of Repair: Example

PAINT SHOP T/M MAKING REPAIR IN

SPOT REPAIR BOOTH.

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