What is Waste or muda is

anything that does not

Waste? add value or service to
the product

Waste is something the

customer will not pay
for.
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D – Defect
O – Over Production
W – Waiting
N – Non Utilized Talent
T – Transport
I – Inventory
M – Motion
E – Excess Process
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A product or information that does not meet customer

DEFECTS expectations.

 Damaged, improperly functioning product, missing or

(Ex. Takata) inaccurate paper work, poor quality, late deliveries, or
rework.

Causes of Defects:
• No standards for inspection work
• Omission of standards operations
• Material handling and conveyance
How to Eliminate Defects:
• Standard operations
• Mistake-proofing devices
• Building quality in at each process
• Promotion of value analysis and value
engineering
• Flow Production
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Converting material or information before it is needed by
end user or downstream customer.

 It applies to WIP and finished goods.

OVER PRODUCTION
Causes of Overproduction
• Large-lot production
• Producing product in advance of demand
• Overstaffing, too much equipment

How to eliminate Overproduction

• Line balancing (Supply = Demands)
• One-piece flow
• Quick changeover operations
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A Person or machine idle due to lack of information or
material required to continue operation.

Causes of Waiting
• Obstruction of flow
• Poor equipment layout
• Capacity imbalances
• Trouble at the upstream processes

WAITING How to eliminate Waiting

• Production leveling
• Product-specific layout
• Mistake-proofing
• Human automation
• Quick changeover
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Omitting, neglecting, ignoring or misusing the best

NON-
resources available for the application at the time.

 Not using the best talent, equipment, machines, or

software.
UTILIZED Examples of Non-utilized Talent

TALENT • Poor Communication

• Failure to involve people in workplace
• Lack of team training
(or) • Poor management

NEGLECTED
RESOURCES
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Unnecessary movement of product or information that
does not add value to meet the customer’s requirements.

Common transportation waste

• Poor layouts – Large distance between operation
• Long material handling system
• Multiple storage facilities

TRANSPORTATI
• Poorly design production system
Effects of Transportation Waste:
• Excess human effort
• Excess Time consumption
ON • Excess Inventory Holdup.
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Material or initial information in a process queue.

Raw material and Finished Goods

Causes of Inventory waste

• Large-lot production
• Obstructed flow of goods

INVENTORY
• Upstream process is too fast for the downstream
process.

How to eliminate Inventory waste

• U-shaped manufacturing cells
• One piece flow
• Production levelling
• Regulating the flow of production
• Pull production using kanban
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Unnecessary movement by people that does not add
value to meet customer’s requirements.

Reaching, bending, walking or any other unnecessary

MOTION
movement.

Example of motion waste

• Gathering more tools than necessary
• Unnecessarily complicated procedures
• Process taking lengthier steps than needed
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Producing and providing more features, information or
work than what is required to meet customer’s
requirements.

It includes extra steps done to meet customer

EXCESS
requirements.

Causes of Excess Process waste

• Inadequate study of process

PROCESS • Inadequate study of operation

• Incomplete standardization
• Materials are not studied

How to eliminate Excess process waste

• Review of operation
• Thorough standardization
• More appropriate process design