September 24, 2017

Introduction to Lean Thinking and Identifying Waste

There are seven Types of Waste

  1. Defects
  2. Over production
  3. Transportation
  4. Waiting
  5. Inventory
  6. Motion
  7. Over processing

Examples of Waste

Waste Example Implication
Defective Products

 

parts incorrect from supplier

 

incomplete information

customer complaints

 

rework, scrap, warranty, fire-fighting

Over Production low yield forces 110 to get 100

 

produce more than demand

additional costs built-in

 

obsolescence, count, store

Excessive Inventories inventory investment ‘sleeping’

 

6mo. of paper at every copier

long lead-time, rework, lost

 

high cost, never right size

Excessive Motion 30% time looking for parts, tools

 

paper not next to copier

barriers to adding value

 

ergonomics, safety

Excessive Processing hand finish

functional signatures

ineffective use of skills

 

no decision rules, travel dist.

Transportation bad layout

 

process monuments

invest to cover inefficiency

 

batch processing, no flow

Waiting investment sits for next ‘event’

 

batching, signature cycles

not cost effective

 

inefficiencies built-in

 

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