Waste

Waste Elimination
Contents of an Operation

Value
a ue Added
dded Work
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
currentt operating
ti conditions
diti

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

The 7 Wastes
2
What is Value Added Work?

Work that increases the value of a part.

i that
i.e. th t which
hi h changes
h the
th fit,
fit form
f or function
f ti

e g press
e.g. forge
bend roll
cut point
drill heat treat
form plate
weld glue
paint assemble
polish ….

Maximise these activities

The 7 Wastes
3
What is Hidden Waste?

Work that does not add value but is necessary

y
under the current operating conditions.
¾ tool changeover
g
¾ inspection
¾ parts handling
p g
¾ unavoidable transportation parts
¾ unwrapping of purchased parts

Minimise these activities

The 7 Wastes
4
What is Obvious Waste?
Work that does not add value Inventory Operator movements

and is not necessary.

necessary
1. Overproduction Transportation

2. Waiting Process Defects

3. Transportation
4. Process Waiting

5. Inventory
6. Operator Movements Overproduction

7. Defects

Eliminate these activities

The 7 Wastes
5
7 Wastes - Overproduction
p

1. Making
a g more
o e tthan
a tthe
e custo
customer
e needs
eeds
¾ Making in large batches
¾ Overrunning an unstable process
¾ To produce more than is required*
¾ To produce before required*
* (by internal or external customer)

Overproduction

The 7 Wastes
6
7 Wastes - Waitingg
2. Man
a oor Machine
ac e Waiting
at g
¾ Waiting for material
¾ Waiting for maintenance waiting-time

¾ Waiting for tool change

¾ Waiting for quality check
¾ Waiting for next station
¾ Waiting for quality checks
¾ Non
o value
a ue added worko in cycle
cyc e
¾ Operator inactivity during cycle
¾ Machine inactivity during cycle

The 7 Wastes
7
7 Wastes - Transportation
p

3. Material/parts
3 ate a /pa ts movement
o e e t Transportation

¾ Unnecessary moving or handling of parts.

¾ Handling equipment moving with no parts.
¾ Raw material batch sizes not matching production batch size.
¾ Material stored a long way from point of use.

The 7 Wastes
8
7 Wastes - Process
4. Inefficient
e c e t Process
ocess
¾ Wrong choice of equipment
¾ Bad definition of customer's needs Process
¾ Useless operations
¾ Excessive movement in process cycle
¾ Too frequent inspections
¾ Excessive set-up or downtime
¾ Slow
S o cocomplicated
p cated pprocesses
ocesses
¾ Useless refinement
¾ Bottlenecks
¾ Unbalanced process

The 7 Wastes
9
7 Wastes - Inventoryy
5. Large
5 a ge Stoc
Stocks
s
¾ Stock pile of finished goods Inventory

¾ High WIP
¾ High raw materials
¾ Excessive racking and warehouse space
¾ Excessive handling equipment

Just In Time Just In Case

The 7 Wastes
10
Types of Waste - Inventory

Inventory conceals problems, makes control difficult and

b
obscures the
th opportunity
t it for
f improvement.
i t
¾ Delays action in dealing with faults
and defects Eliminate rocks
¾ Reduces need to face up to fast tool = solve problems
changeovers = eliminate waste
¾ Conceals imbalance in facility
capability
¾ Goods can become damaged or
obsolete
¾ Creates unnecessary searching and Machine
breakdown
Supplier
movement of materials Long
travelling
delivery

¾ Conceals
C excess personnel parts
t

¾ Takes up space

Inventory Costs £££ !

The 7 Wastes
11
7 Wastes - Operator Movements

6. Use
6 Useless
ess motion
ot o
¾ Looking for tools, materials etc
Operator movements
¾ Double handling
¾ Turning
¾ Bending
¾ Stretching
¾ Walking
¾ etc
etc…

The 7 Wastes
12
7 Wastes - Defects
7. Less
ess tthan
a Perfect
e ect Parts
a ts
¾ Scrap
Defects
¾ Rework
¾ Trimming
¾ Rejects
¾ Recalls
¾ Delay due to defects
¾ Transportation
a spo tat o due to de
defects
ects
¾ Re-inspection and sorting
¾ Rework area inside production process
¾ Overtime to meet demand due to poor quality

The 7 Wastes
13
What is Obvious Waste?
Work that does not add value Inventory Operator movements

and is not necessary.

necessary
1. Overproduction Transportation

2. Waiting Process Defects

3. Transportation
4. Process Waiting

5. Inventory
6. Operator Movements Overproduction

7. Defects

Eliminate these activities

The 7 Wastes
14
 Event: Name:
WASTE ANALYSIS
Location:
ocat o Date:
WASTE OBSERVED CAUSE

OVERPRODUCTION

WAITING

TRANSPORT

INEFFICENT PROCESS

INVENTORY

UNNECESSARY
MOVEMENTS

DEFECT