8 Wastes1. Transportation

2. Inventory

3. Motion

4. Waiting

5. Over processing

6. Over production

7. Defects

8. Unused Human Potential

Rapid Site Assessment

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”Transportation

2

Definition: Any movement of product that does not add value

Example: Moving parts in and out of storage, movement of parts between processes

Indicator: Batch Production, push production, large storage areas, functional layout

Action to take: One Piece Flow, VSM, Point of use storage

2

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”Inventory

3

Definition: Any material or product that is not needed to satisfy the current customer demand

Example: Excess raw materials, work in process, finished goods,

Indicator: Long supplier lead times, lack of visible flow, long setups, no ordering process on shop floor

Action to take: Pull Systems, One Piece Flow, VSM, SMED

3

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”Motion

4

Definition: Any movement of people that does not add value

Example: Searching for parts/tools/prints, sorting materials, reaching for tools, lifting parts/boxes

Indicator: Workplace disorganization, poor workstation design, unsafe workspaces, missing items

Action to take: 5S, Hoshin, VSM, Point of Use Storage, Water-Spider

4

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”Waiting

5

Definition: Idle time created when material, information, people or equipment are not ready

Example: Waiting for parts, prints, inspection, machines, repairs, information

Indicator: Push production, work imbalance, centralized inspection, high downtime, no visible production plan

Action to take: Work Balancing, SMED, TPM, In process Inspection

5

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”Over processing

6

Definition: Any effort that adds no value from the customers viewpoint

Example: Multiple cleaning of parts, over-tight tolerances, paperwork

Indicator: Delays between processes, No DFM process involving employees, No standardized work

Action to take: VSM, One Piece Flow, Standardized Work

6

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”Overproduction

7

Definition: Producing more that the customer needs right now

Example: Producing to forecast, producing to avoid setups, batch production

Indicator: Forecast on shop floor, long setups, inventory to cover breakdowns

Action to take: Pull Systems, Work Balancing, Hourly Takt Targets, SMED

7

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”Defects

8

Definition: Any effort to contain, rework or disposition mistakes or errors

Example: Scrap, rework, customer returns, supplier rejects

Indicator: Processes not defined and stable, Poor handling and tracking of rejects/rework, Internal and external defect rates not visible

Action to take: Standardized Work, DM Process, Customer Focus Area, Shop Floor Problem Solving

8

Upper longeron location in F-15 forward fuselage                                  

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”Unused Human Potential

9

Definition: Any Losses due to lack of utilization of the entire team in continuous improvement

Example: No cross-functional teams, top-down management, no suggestion programs

Indicator: No Team communication areas, poor understanding of priorities, employee resistance to new ideas

Action to take: 5S, Daily Team Meeting, Suggestion System, QRQC

9

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Example - Scorecard

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Example - Scorecard