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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