Waste is anything that does not contribute to transforming a part to the customers needs.
Waste is anything that doesn't add value but adds only cost to the product.
Essentially a "waste" is anything that the customer is not willing to pay for.
Tow types of actions for WASTE-
- Waste= can be 100% eliminated
- Waste= can be reduced or simplified
Waste has major effect on ......
- Labor utilization ......to maximize labor working time
- Machine utilization ...to maximize NDT(needle down time)
- Space utilization .......to reduce cost related to WIP, Inventories etc.
Type of waste -
- Over production
- Over processing
- Rework
- Waiting
- Excess Inventory
- Excess motion
- Excess transportation
- Dis-connectivity
OVER PRODUCTION -
Running a machine to produce product that is not needed for next process. Over Production means making more than is required by the next process,making earlier than is required by the next process or making faster than is required by the next process.
Producing more than is needed, faster than needed or before needed - all are Over Production.
Causes for overproduction -
- Wrong takt time
- Long process setup
- Unleveled schedule
- Unbalanced work load
- Poor planning
- Lack of communication etc.
OVER PROCESSING -
Work process or materials that add no value to the product from the customer,s viewpoint.
Doing more work than necessary to meet the customer needs or requirements.
Redundant effort (production or communication) which does not adds value to a product or service.
Causes of over processing -
- Product change without process changes
- Lack of communications
- Raw material approvals
- Rely on paper and extra copies
- Customer requirements not defined
- Lack of process standardization etc.
REWORK -
Rework means any repair or additional work performed outside the operators normal work.
Repair or rework of a product or service to fulfill customer requirement.
Reworks are -
- Wrong size or fit
- Pieces cut wrong
- Incorrect information
- Drawn incorrectly
- Customers needs not understood
- Poor quality
- Weak processes control
- Unbalanced inventory level
- Deficient planed maintenance
- Inadequate education or training
WAITING -
Any idle time which is not performing work for goods or services. It may be -
- for the next product
- for the materials
- for the assistant
- for equipments
- for information etc.
Causes of waiting -
- Unbalanced work load
- Unplanned maintenance
- Long process set up
- Miss-uses of automation
- Upstream quality problem
- Unleveled scheduling etc.
EXCESS INVENTORY -
Material between operations due to large lot production or processes with cycle time.
Any supply in excess of process requirements necessary to produce goods or services in a Just-in-Time manner.
Materials sits taking up space, costing money and potentially being damaged.
It may be-
- Raw materials in storage
- Materials and supplies in storage
- Materials at the process
- Finished goods stored prior to shipping etc.
Causes of excess inventory
- Product complexity
- Unleveled scheduling
- Poor market forecast
- Unbalanced workload
- Unreliable shipments by suppliers
- Misunderstood communication
- Reward system
EXCESS MOTION -
Any movement of people which does not contribute added value to the product or service.
Any motion that does not add value to the product.
It may be-
- Walking from point to point during the work cycle
- Reaching to pick materials
- Turning or bending of body
- Matching parts
- Repeat evacuation motion
- Excessive travel distance
- Inconsistent work method
- Unfavorable facility or cell layout
- Poor work place organization and house keeping
- Extra "busy" movements while waiting
- Poor people or machine effectiveness etc.
EXCESS TRANSPORTATION -
Any material movement that does not directly support immediate production.
Moving the materials which does not enhance the value of the product to the customers.
It may be-
- The movement of materials, weather manual or automatic
- Moving materials to and from the warehouse, movement materials at the process.
- Handling and carrying paper work between operations.
- Poor plant layout
- Poor understanding of the process flow for production
- Large batch size
- Long lead time
- Large storage areas etc.
DIS-CONNECTIVITY -
Waste is anything that does not contribute to transforming a part to the customers needs.
Waste is anything that doesn't add value but adds only cost to the product.
Essentially a "waste" is anything that the customer is not willing to pay for.
Tow types of actions for WASTE-
Waste has major effect on ......
Type of waste -
OVER PRODUCTION -
Running a machine to produce product that is not needed for next process. Over Production means making more than is required by the next process,making earlier than is required by the next process or making faster than is required by the next process.
Producing more than is needed, faster than needed or before needed - all are Over Production.
Causes for overproduction -
OVER PROCESSING -
Work process or materials that add no value to the product from the customer,s viewpoint.
Doing more work than necessary to meet the customer needs or requirements.
Redundant effort (production or communication) which does not adds value to a product or service.
Causes of over processing -
REWORK -
Rework means any repair or additional work performed outside the operators normal work.
Repair or rework of a product or service to fulfill customer requirement.
Reworks are -
WAITING -
Any idle time which is not performing work for goods or services. It may be -
Causes of waiting -
EXCESS INVENTORY -
Material between operations due to large lot production or processes with cycle time.
Any supply in excess of process requirements necessary to produce goods or services in a Just-in-Time manner.
Materials sits taking up space, costing money and potentially being damaged.
It may be-
Causes of excess inventory
EXCESS MOTION -
Any movement of people which does not contribute added value to the product or service.
Any motion that does not add value to the product.
It may be-
EXCESS TRANSPORTATION -
Any material movement that does not directly support immediate production.
Moving the materials which does not enhance the value of the product to the customers.
It may be-
DIS-CONNECTIVITY -
Waste is anything that doesn't add value but adds only cost to the product.
Essentially a "waste" is anything that the customer is not willing to pay for.
Tow types of actions for WASTE-
- Waste= can be 100% eliminated
- Waste= can be reduced or simplified
Waste has major effect on ......
- Labor utilization ......to maximize labor working time
- Machine utilization ...to maximize NDT(needle down time)
- Space utilization .......to reduce cost related to WIP, Inventories etc.
Type of waste -
- Over production
- Over processing
- Rework
- Waiting
- Excess Inventory
- Excess motion
- Excess transportation
- Dis-connectivity
OVER PRODUCTION -
Running a machine to produce product that is not needed for next process. Over Production means making more than is required by the next process,making earlier than is required by the next process or making faster than is required by the next process.
Producing more than is needed, faster than needed or before needed - all are Over Production.
Causes for overproduction -
- Wrong takt time
- Long process setup
- Unleveled schedule
- Unbalanced work load
- Poor planning
- Lack of communication etc.
OVER PROCESSING -
Work process or materials that add no value to the product from the customer,s viewpoint.
Doing more work than necessary to meet the customer needs or requirements.
Redundant effort (production or communication) which does not adds value to a product or service.
Causes of over processing -
- Product change without process changes
- Lack of communications
- Raw material approvals
- Rely on paper and extra copies
- Customer requirements not defined
- Lack of process standardization etc.
REWORK -
Rework means any repair or additional work performed outside the operators normal work.
Repair or rework of a product or service to fulfill customer requirement.
Reworks are -
- Wrong size or fit
- Pieces cut wrong
- Incorrect information
- Drawn incorrectly
- Customers needs not understood
- Poor quality
- Weak processes control
- Unbalanced inventory level
- Deficient planed maintenance
- Inadequate education or training
WAITING -
Any idle time which is not performing work for goods or services. It may be -
- for the next product
- for the materials
- for the assistant
- for equipments
- for information etc.
Causes of waiting -
- Unbalanced work load
- Unplanned maintenance
- Long process set up
- Miss-uses of automation
- Upstream quality problem
- Unleveled scheduling etc.
EXCESS INVENTORY -
Material between operations due to large lot production or processes with cycle time.
Any supply in excess of process requirements necessary to produce goods or services in a Just-in-Time manner.
Materials sits taking up space, costing money and potentially being damaged.
It may be-
- Raw materials in storage
- Materials and supplies in storage
- Materials at the process
- Finished goods stored prior to shipping etc.
Causes of excess inventory
- Product complexity
- Unleveled scheduling
- Poor market forecast
- Unbalanced workload
- Unreliable shipments by suppliers
- Misunderstood communication
- Reward system
EXCESS MOTION -
Any movement of people which does not contribute added value to the product or service.
Any motion that does not add value to the product.
It may be-
- Walking from point to point during the work cycle
- Reaching to pick materials
- Turning or bending of body
- Matching parts
- Repeat evacuation motion
- Excessive travel distance
- Inconsistent work method
- Unfavorable facility or cell layout
- Poor work place organization and house keeping
- Extra "busy" movements while waiting
- Poor people or machine effectiveness etc.
EXCESS TRANSPORTATION -
Any material movement that does not directly support immediate production.
Moving the materials which does not enhance the value of the product to the customers.
It may be-
- The movement of materials, weather manual or automatic
- Moving materials to and from the warehouse, movement materials at the process.
- Handling and carrying paper work between operations.
- Poor plant layout
- Poor understanding of the process flow for production
- Large batch size
- Long lead time
- Large storage areas etc.
DIS-CONNECTIVITY -
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