8 deadly muda_(shut your mouth!)
TRANSCRIPT
8 Wastes To EliminateIn Order to Lean Out
Your ProcessesLin Fisher, CSM
Defects
Production Examples:• Unclear customer specifications• Incapable processes• Lack of process control• Unskilled personnel• Departmental rather than total
company quality improvement initiatives
• Incapable suppliers
Service Examples:• Rejections in sourcing applications• Incorrect data entry
Strategies to reduce:• Design review• Reduce defective materials• Train employees• Maintenance of machines and
equipment
Waiting
Production Examples:• Unsynchronized processes; line
imbalance• Inflexible workforce• Over staffing• Unscheduled machine downtime• Long setup times• Material shortage or delay• Manpower shortage or delay
Service Examples:• Customers waiting to be served
in a contact centre• System downtime
Inventory
Production Examples:• Overproduction• big batch sizes• Long lead times• Local optimization (turf mentality)• Large minimum order quantities• High rework rate (ties into defects)• Just In Time (JIT) incapable suppliers• Lack of material requisition and issuance
standards
Service Examples:• Files and documents waiting to be
processed• Excess promotional materials sent to
market• More infrastructure than required
Strategies to reduce:• Dispose of obsolete material to
save space and avoid confusion• Do not produce items ahead of
customers delivery requirements• Do not manufacture products in
excess of customer's requirements
Motion
Production Examples:• Poor workstation layout - excessive bending,
walking and reaching• Poor method design - transferring parts from
one hand to another• Reorientation of materials• Poor layout and housekeeping• Disorganized workplace and storage locations• Unclear, non-standardized work instructions• Unclear process and materials flow
Service Examples:• Looking for data and information• Movement of people to and from office
equipment
Strategies to reduce:• Motion economy principal• Effective supervision
Over ProcessingProduction Examples:• Unclear customer specifications• Frequent engineering changes• Excessive quality (refinements,
"polishing")• Inadequate value analysis/value
engineering• Unclear work instructions
Service Examples:• Too much paperwork in process• Same data required in multiple places
in a process• Follow up coordination costs• Too many approvals• Reporting overburden
Strategies to reduce:• Improve work allocation• Identify more effective methods• Limit overproduction
Over Production
Production Examples:• Volume incentives (sales, pay, purchasing)• High capacity equipment• Poor scheduling/shifting• Poor production planning• Cost accounting practices that encourage
build up of inventory
Service Examples:• Information sent automatically even when
not required• Printing documents before they are
required• Processing items before they are required
by the next person in the process
Strategies to reduce:• Strong production planning and
control• Production according to
customer schedule• Firm delivery requirements
Underutilized Talent
Production Examples:• Inappropriate policies• Incomplete measures• No time made available in operators work
schedule• Problem solving only done with "experts"
ignoring employees• Top down improvement ideas
Service Examples:• Limited authority and responsibility• Person put on a wrong job
Strategies to reduce:• Give staff ownership of work