Waste

Waste Elimination

Contents of an Operation
Value Added Work a ue dded o
The part of the job the customer wants to pay for

Non Value Added or Hidden Waste

Work that does not add value but is necessary under the current operating conditions t ti diti

Obvious Waste
Work that does not add value and is not necessary
WASTE

The7Wastes

What is Value Added Work?

Work that increases the value of a part. i.e. th t hi h h i that which changes the fit, form or function th fit f f ti

e.g. e g press bend cut drill form weld paint polish

forge roll point heat treat plate glue assemble .

Maximise these activities

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What is Hidden Waste?

Work that does not add value but is necessary y under the current operating conditions. tool changeover g inspection p parts handling g unavoidable transportation parts unwrapping of purchased parts

Minimise these activities

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What is Obvious Waste?

Work that does not add value and is not necessary. necessary 1. Overproduction 2. Waiting 3. Transportation 4. Process 5. Inventory 6. Operator Movements 7. Defects
Process Inventory Operator movements

Transportation

Defects

Waiting

Overproduction

Eliminate these activities

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7 Wastes - Overproduction p
1. Making more t a t e custo e needs a g o e than the customer eeds
Making in large batches Overrunning an unstable process To produce more than is required* To produce before required* * (by internal or external customer)

Overproduction

The 7 Wastes

7 Wastes - Waiting g
2. Man o Machine Waiting a or ac e a t g
Waiting for material Waiting for maintenance Waiting for tool change Waiting for quality check Waiting for next station Waiting for quality checks Non value added work in cycle o a ue o cyc e Operator inactivity during cycle Machine inactivity during cycle
waiting-time

The 7 Wastes

7 Wastes - Transportation p
3 ate a /pa ts o e e t 3. Material/parts movement
Transportation

Unnecessary moving or handling of parts. Handling equipment moving with no parts. Raw material batch sizes not matching production batch size. Material stored a long way from point of use.

The 7 Wastes

7 Wastes - Process
4. Inefficient Process e c e t ocess
Wrong choice of equipment Bad definition of customer's needs Useless operations Excessive movement in process cycle Too frequent inspections Excessive set-up or downtime S o complicated processes Slow co p cated p ocesses Useless refinement Bottlenecks Unbalanced process
Process

The 7 Wastes

7 Wastes - Inventory y
5 a ge Stocks 5. Large Stoc s
Stock pile of finished goods High WIP High raw materials Excessive racking and warehouse space Excessive handling equipment
Inventory

Just In Time
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Just In Case
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Types of Waste - Inventory

Inventory conceals problems, makes control difficult and b th t it f i t obscures the opportunity for improvement. Delays action in dealing with faults and defects Reduces need to face up to fast tool changeovers Conceals imbalance in facility capability Goods can become damaged or obsolete Creates unnecessary searching and movement of materials Conceals excess personnel C Takes up space
Eliminate rocks = solve problems = eliminate waste

Machine breakdown

Supplier Long delivery travelling parts t

Inventory Costs !
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7 Wastes - Operator Movements

6 Useless ot o 6. Use ess motion
Looking for tools, materials etc Double handling Turning Bending Stretching Walking etc etc
Operator movements

The 7 Wastes

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7 Wastes - Defects
7. Less t a Perfect Parts ess than e ect a ts
Scrap Defects Rework Trimming Rejects Recalls Delay due to defects Transportation due to de ects a spo tat o defects Re-inspection and sorting Rework area inside production process Overtime to meet demand due to poor quality

The 7 Wastes

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What is Obvious Waste?

Work that does not add value and is not necessary. necessary 1. Overproduction 2. Waiting 3. Transportation 4. Process 5. Inventory 6. Operator Movements 7. Defects
Process Inventory Operator movements

Transportation

Defects

Waiting

Overproduction

Eliminate these activities

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