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Overproduction Waste-finding Checklist

Description of Waste No production schedule or control boards No leveling of production schedule Production not in sync with production schedule Items missing Defective goods produced Equipment breakdowns Too much manual assistance required Machines have too much capacity Lots are grouped into batches Using "push" production Caravan style operations Not balanced with next process Yes No Magnitude Causes and/or Improvement Plans

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Inventory Waste-finding Checklist


Description of Waste Lots of inventory on shelves and floors Shelf and floor storage takes up lots of space Inventory stacks block walkways In-process inventory accumulates within individual operations In-process inventory is stacked up between operations In-process inventory is stacked up between processes Impossible to visually determine quantities of in-process inventory Yes No Magnitude Causes and/or Improvement Plans

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Transportation Waste-finding Checklist


Description of Waste Pile up during transportation Change of transportation devices mid transfer Previous and/or nex process is on another floor Transportation requires manual assistance Transportation distance is too long Yes No Magnitude Causes and/or Improvement Plans

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Defect Waste-finding Checklist


Description of Waste Complaints from next process Defects within the process Human error Defects due to missing part(s) Defects due to wrong parts(s) Omission(s) in processing No human automation No mistake-proofing No inspection within process Defects not addressed by improvement activities Yes No Magnitude Causes and/or Improvement Plans

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Overprocessing Waste-finding Checklist


Description of Waste Process is not required for product function Process includes unnecessary operations Process can be replaced by something less wasteful Part of process can be eliminated without detracting from product Yes No Magnitude Causes and/or Improvement Plans

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Operation Waste-finding Checklist


Description of Waste Walking Turning around Leaning sideways Bending over Too wide arm movements Unnecessary wrist movements Left or right hand is idle Poorly untilized idle time Wasteful work piece setup/removal Non-standardized repetition of operations Worker operates using different motions each time Operations divided into too many little segments Yes No Magnitude Causes and/or Improvement Plans

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Idle Time Waste-finding Checklist


Description of Waste Work piece delay from previous process Maching busy status Missing item(s) Lack of balance with previous process Lack of planning Lack of standard operations Worker absence Too many workers Yes No Magnitude Causes and/or Improvement Plans

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