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Learn what the Seven Deadly Wastes are and how they affect our business. Identify the Waste in our business and develop an action plan to eliminate it. Develop an action plan to teach others what the Seven Deadly Wastes are and how to eliminate them.
Have you heard of Mass Production? This method of production was brought to the forefront with Henry Fords invention of the automobile.
Mass Production Lean Manufacturing
Skilled Craftsmanship
1900s
1930s
1960s
TODA Y
How are cars from Japan viewed today? Welcome the age of Lean Manufacturing.
In the early 1960s TPS was pioneered by Taiichi Ohno to reflect the philosophies of waste elimination and time management Highly skilled work cell jobs Emphasis on quality and efficiency
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The team must embrace a philosophy of having zero tolerance for waste Activity on a daily basis is focused on creating a stable production environment. Systems are set up to create customer Pull or Just-in-Time Delivery
The highest quality product can only be achieved in a stable environment. Problems are instabilities that must be surfaced quickly and solved permanently Standardization, consistency and predictability and repeatability are the goals. Improve from there!
A product should only be built to meet customers demands. Build only what the customer wants, deliver it when it is expected and with perfect quality This approach results in the best use of the companys resources, which leads to greater profitability
Dough, Sauce, Toppings, Toppings dropped on the floor, Labor cost for delivery driver, Labor cost for delivery driver to stop at girlfriends house on the way? What are our customers willing to pay for?
WASTE
Overproduction
Overproduction is making more of something than the customer requested
Examples:
Running a machine for 16 hours when only 10 are required Making 2 days worth of product when only 1 days worth is required
Inventory
Inventory waste occurs when there is more product on hand than the customer requested.
Examples:
More raw material than needed for smooth production More work-in-process
Transportation
Transportation waste is moving the product more than is necessary
Examples:
Having three storage locations for the same material Moving raw materials to an offsite warehouse
Waiting
Anytime value cannot be added because of a delay is defined as the waste of waiting
Examples:
Waiting for material Waiting for a machine to be fixed Unbalanced assembly sequence
Motion
The waste of motion refers to any extra movement of the operator when they are performing the work sequence (excessive or repetitive motion also increases ergonomic issues)
Examples:
Walking 10 feet to retrieve a part or tool Twisting around to grab a part in the back of the workstation
Overprocessing
Over processing is doing more to the product than the customer requested
Examples:
Plating a product for four hours when only two are required Testing a product three times when the specification calls for one test
Correction/Rework
Anything that is not done right the first time and requires rework inspection or touchup (Also includes scrap and appearance issues )
Examples:
Re-torquing a bolt Sorting incoming materials Checking a key dimension Trimming thread or flash from a component
Waste in my cell!!
Correction Overproduction
Transportation
Waiting
Over Processing
Motion
Inventory
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