STM Quality

Limited

7 Wastes

TOTAL QUALITY MANAGEMENT

7 Wastes
©©ABSL Power Solutions
STM Quality Limited 2007
 STM Quality
Waste Limited

How often have you used the

expressions:

“That was a waste of time!”

or
“That was a waste of money!”
or
“That was a waste of effort!”
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 STM Quality
Wasted Time Limited

Just imagine if we
could collect all
the time
together that we
have wasted in
the past -
How much time
would that be?

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 STM Quality
Wasted Money Limited

Just imagine if we
could collect all
the money
together that we
have wasted in
the past -
How much money
would that be?

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 STM Quality
Wasted Effort Limited

Just imagine if we
could collect all
the effort
together that we
have wasted in
the past -
How much effort
would that be?

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 STM Quality
The Problem With Waste Limited

The problem with wasted time, money &

effort is:

When it’s gone…

- it’s gone!

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 STM Quality
Eliminating Waste Limited

 So what can we do to eliminate

waste?

 We first need to identify what is &

is not waste, then we can look at
ways of eliminating or at least
reducing waste.

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 STM Quality
Identifying Waste in the Workplace Limited

Operational Activity
Value added Operations
 Any process that changes the nature,
shape or characteristic of the product in
line with customer requirements
 e.g. Pressing, welding, heat treatment.

This is where we make a profit!

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 STM Quality
Identifying Waste in the Workplace Limited

Operational Activity
Non-Value added Operations
 Work carried out which is necessary under
current conditions, but does not increase
product value.
 e.g. Inspection, tool change, maintenance.

This is where we make a loss!

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 Value Added and STM Quality
Non-Value Added operations Limited

 The objective is to raise the ratio of Value

added operations to non-value added
operations and eliminate waste.
OPERATOR TIME
VALUE
WASTE NON-VALUE ADDED
ADDED
ELIMINATE

MORE TIME FOR NON-VALUE VALUE

OTHER ACTIVITIES ADDED ADDED

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 STM Quality
7W – The Elimination of Waste Limited

 So, now we understand the difference in

value added & non-value added
operations, what are the benefits in
eliminating all waste?

• Reduced costs
• Greater Capacity
• Bottlenecks are identified

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 STM Quality
7W – 7 Types of Waste Limited
 1 Over-production
 2 Inventory
 3 Transportation
 4 Process
 5 Idle Time
 6 Operator Motion
 7 Bad Quality
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 STM Quality
7W – 1. Over-production Limited
 Over-production

 Producing more than is needed hides a

multitude of problems. Excessive set-up times,
machine faults, risk of producing obsolete
stock.

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 STM Quality
7W – 2. Inventory Limited
 Inventory

 Carrying stock attracts cost & storage problems.

Storage leads to stacking, racking, sophisticated
computers, bar coding & automation, all for an
activity that adds no value to the product.

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 STM Quality
7W – 3. Transportation Limited
 Transportation

 This may appear unnecessary but does add

value. Large transport is easily identified but
small transport such as manual labour may not
be so noticeable. These can be improved by
changes to the work environment.
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 STM Quality
7W – 4. Process Limited
 Process

 Adds cost but no value - e.g.trimming &

moulding to a level that is beyond the required
standard adds extra time that customers do
not want to pay for.

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 STM Quality
7W – 5. Idle Time Limited
 Idle Time

 Typically, waiting for products & services from

preceding operations, waiting for work from
their previous set-up or waiting for cycles to
finish, or meetings to start.

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 STM Quality
7W – 6. Operator Motion Limited
 Operator Motion

 Typically, single handed operations where

both should be used, stretching unnecessarily
or awkwardly and walking between things. All
of these take time or use time poorly, none add
value.

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 STM Quality
7W – 7. Bad Quality Limited
 Bad Quality

 Rejects are always produced by systems and

procedures created by management. If
operators fail it is because the process allowed
them to fail through inadequate training or
because the process was not capable in the
first place.
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 STM Quality
7W – The Elimination of Waste Limited

 So, now we understand the 7 wastes, we can:

• Produce only what is needed;
• Carry only essential stock;
• Use transportation more wisely;
• Produce work to the standard required;
• Plan our production processes;
• Put our efforts to the best possible use;
• Train to make quality work every time!

© STM Quality Limited