7 Types of Waste– Correction– Overproduction– Movement of Material & Information

– Waiting– Inventory– Processing

Lean Principle: All waste is eliminated

OverproductionThere are 2 types of over-production: both are wasteful. One is producing a larger amount than the order requires. The other is producing goods at a rate faster than they are needed.

# 1

(Overproduction is the most significant form of waste!)

#2Correction

When work is not performed correctly the first time, resources are used to correct the defect. Resources are used again and again to address quality problems that may surface later

MotionAny movement of people or machinery, which does not contribute added value to the product is considered waste.

#3

Material MovementApplies to the delivery of materials and parts to the supply of information. Any movement of material and product that does not support the “Just-In-Time” production is a form of waste.

#4

WaitingThis is “idle” time that occurs in process line that is not efficiently organized; or when an operator must wait for a machine to complete an automatic process or for the delivery of parts to the workstation.

#5

InventoryInventory must be adjusted to the actual need or the “JUST-IN-TIME” production schedule. An excess of parts between work processes or too many parts delivered by suppliers is considered waste.

#6

ProcessingUnnecessary processing of work does not improve the quality of the product.

#7

Apply Lean to your Life

PressAlarm

Brush Teeth

Get outof bed

Walk toKitchen

EatBreakfast

Walk toRoom

PressAlarmSnooze

TakeShower

FindClothes

Find workMaterials

Put onClothes

LeaveHouse

5 s

150 s300 s

20 s10 s5 s

30 s

300 s

30 s 20 s 10 s

20 s 300 s

Total Cycle Time : 1200 s= waste

Apply Lean to your Life

PressAlarm

Brush Teeth

Get outof bed

Walk toKitchen

EatBreakfast

TakeShower

Find workMaterials

Put onClothes

LeaveHouse

5 s 150 s 300 s

20 s

10 s 30 s

10 s10 s 300 s

Total Cycle Time: 835 s30% ImprovementEXTRA 6 min a day!!!= 1.5 days a year30%

Process Mapping

•Understanding the use of Process Mapping.

•How to construct a Process Flow Chart.

•Understanding the use of Process Mapping.

•How to construct a Process Flow Chart.

Objectives

Process Mapping

•Process Map is a graphical presentation of the flow of a process. A detailed process map contains information that is beneficial to improving the process

OPERATION

TRANSPORTATION

STORAGE

INSPECTION

DECISION

Good

BadBad

Scrap

WarehouseWarehouse

••How many Operational Steps are there?How many Operational Steps are there?••How many Decision Points?How many Decision Points?••How many Measurement/Inspection Points?How many Measurement/Inspection Points?•• How many Re-work Loops?How many Re-work Loops?

Good

Basic Process Flow