WASTE ELIMINATION

3Ms
MUDA
MURI
MURA

LEANMANAGEMENT

LeanManagementor"Lean"istheoptimalwayofmanagingthroughthe
removalofwasteandimplementingflow.
Itisrenownedforitsfocusonreductionoftheoriginalprocesswastesin
order toimproveoverallcustomervalue.
Insimpleterm,morevaluewithlesswork.
LeanmanufacturingisderivedmostlyfromtheToyotaProductionSystem
(TPS)Identifiedas"Lean"onlyafter1990s.
Goalistoeliminatethewastefromtheprocess.

WHATISLEAN?

TOYOTAPRODUCTIONSYSTEM

Makewhatthecustomerneeds,whenitisneeded,intheright
amount.

Minimizeinventories

Separatemachineworkfromhumanworkandfullyutilizeboth

Buildqualityintotheprocessandpreventerrorsfromhappening

Reduceleadtimestoallowforrapid,flexiblescheduling

Produceahighmixoflowvolumeproductsefficiently

LEANPRODUCTION TPS
MaingoalsofToyotaProductionSystem(TPS)aretoeliminate:

Overburdenorstressinthesystem(muri)

Inconsistency(mura)

Waste(muda)
Goalistodesignaprocessthatrunssmoothly,canflexwithoutstress,and
eliminateswaste.
UsingTPS,Toyotawasabletoreduceleadtimeandcost,whileimproving
quality.

Eliminating 3M

MUDA (Waste)
MURI
(Strain / Over burden)
MURA (Unevenness)

MUDA
MUDAistheWaste,workthatdoesnotaddanyvaluetotheproduct

Input

Process-1
W

V Process-2
W

V Process-3
W

V Process-4 V

Product

V:Valueaddedproduct/services
W:Wastefulproduct/practices/servicesthatdoesnotaddvalue

EconomicValueofWaste
Every business activity absorbs

resources and every resource has

a cost

Every waste has a cost, and that

is direct loss to the company.

Economic value of waste in a

process industry are in the range

of 10 35% of annual turnover

7SevenMUDA[Wastes]
UnnecessaryMotions
Waitingforworkandmaterials
Transportations
Overproduction
Processing
Inventories/UnnecessaryWIP
Correctiveoperation

ELIMINATINGMUDA
Motion: usingunnecessarymovementandenergyusedtoperformtasks.
Waiting:workersrenderedidlebyexcessivesetuporequipmentbreakdowns.
Transport:poortiming;toofrequentorinfrequentmovementofgoodsand deliveries.
Overproduction:Producingitemsnotimmediatelyneeded.
Processing:imposinginefficientandunnecessarytasks;failingtosynchronizesystems.
Inventory:stockingitemsnotimmediatelyneeded.
Correction/Repair:Producingdefectiveproducts.

MUDAofMotion

MUDAofMotion
Movement that does not add value
Searching for files
Extra clicks or key strokes
Clearing away files on the desk
Gathering information
Looking through manuals and catalogs
Handling paperwork

MUDA of Waiting

MUDAof
Waiting

MUDAofWaiting

Idletimecreatedwhenmaterial,information,peopleor
equipmentisnotready.
Waitingfor:

Faxes
Thesystemtocomeback
Copiermachine
Customerresponse
Ahandedofffiletocomeback

MUDAofTransport
I am more expensive
since raw material is
coming from a far
off place.

MUDAofTransport
Movementofinformationthatdoesnotadd
value:
Carryingdocumentstoandfrofromshared

equipment
Takingfilestoanotherperson
Goingtogetsignatures

the more, the

merrier

MUDAofOver
production
Generatingmoreinformationthanthecustomerneeds
rightnow:

Moreinformationthanthecustomerneeds
Creatingreportsnoonereads
Makingextracopies
Moreinformationthanthenextprocessneeds

MUDAofProcess
1. Usingmoreexpensive
equipmentortoolswhere
simpleroneswouldsuffice.
2. Havingmeetingsthatarenot
needed.
3. Havingpeopleatmeetings
thatarenotrequired.
4. Agendapoints,nottobe
included;

MUDAof
Process
Effortsthatcreatenovaluefromthecustomer
viewpoint:

Creatingreports
Repeatedmanualentryofdata
Excessivepaperwork
Duplicityofwork
Useofoutdatedstandardforms
Useofinappropriatesoftware

Moreinformation,project,materialonhandthan
thecustomerneedsrightnow:
Fileswaitingtobeworkedon
Openprojects
Officesupplies
Emailswaitingtoberead
Unusedrecordsinthedatabase

MUDAofCorrection

Workthatcontainserrors,rework,mistakesor
lackssomethingnecessary:
Dataentryerror
Pricingerror
Missinginformation
Missedspecifications
Lostrecords
Rework
Reschedulingmeetings

Howtoeliminate?

FindtheRootCause
AskingWHYfor5times
5W1H

5W1HofMUDA
Who
1. Who does it?
2. Who is doing it?
3. Who should be doing it?
4. Who else can do it?
5. Who else should do it?
6. Who is doing 3-Mus?

What
1. What to do?
2. What is being done?
3. What should be done?
4. What else can be done?
5. What else should be done?
6. What 3-MUs are being
done?

Where
1. Where to do it?
2. Where is it done?
3. Where should it be done?
4. Where else can it be done?
5. Where else should it be
done ?
6. Where are 3- MU s being
done?

MURI
Muri is the overburden on equipment, facilities & people caused
mura and muda.

by

This is in some respects on the opposite end of the spectrum of

muda.

Muri is pushing a machine or person beyond natural limits.

Overburdening people results in safety and quality problems.

Overburdening equipment causes breakdowns and defects

IdentifyingMURI
MURI = Physical Strain, Overbourden
Bend to work?
Push hard?
Lift weight?
Repeat tiring action?
Wasteful walk?
Placingofexcessivedemandson
People
M/Cs,Productionequipment.
Muriiscausedbytherespectofunsuitedstandards

MURA
Mura is the variation in the operation of a process not
caused by the end customer.
It is the unevenness, unbalanced work on machines.
Mura results when employees are told to work like crazy
early in the morning only to stand around and do nothing
late in the day.

Result: Excess capacity allocation and increased cost.

Eliminating MURA
Happens sometimes?
Happens some places
Happens to some people
One side is ok; the other side is not ok

MURA

is
Inconsistent or
Irregular or
Uneven use of person or M/c.

Quality
Doesnt happen by
Accident,
It has to be
Planned