Word Doc- 8 Types Of Wastes

The 8 Types of Waste • • • • • • • •

Overproduction Inventory Transportation Motion (Operations) Processing Defects / Quality Waiting People’s Skills

Overproduction 1. Supplying the process with more than is needed to meet order requirements, sooner and faster than it is needed, causes almost all other types of waste 2. This is the worst waste of all, because it helps cause all the others Common causes: a) Producing more than is required to make up for yield loss b) Scheduling production to forecasted demand c) Long changeovers or avoiding changeovers lead to large lot production

Inventory 1. Requires people, equipment and space to count, transport, store and maintain it 2. If we do not get orders the material will become obsolete, and be thrown away 3. Inventory is often used to help hide other wastes Common causes: a) Overproduction b) Poor equipment layout c) Long changeover times d) Defective, or questionable, parts e) Mismatched production speeds

Transportation 1. Double or triple handling, moving in and out of storage areas and warehouses 2. Material can get damaged if it’s moved too much 3. It adds no value and is often used to get the extra inventory out of the way Common causes: a) Extra Inventory b) Retention points before and after operations c) Excessive distance between operations (layout) d) Single skill focused operations

Motion (Operators) 1. 2. 3. 4.

Walking without working (away from workstation) Searching for tools, materials or information Reaching, bending or unnecessary motion due to poor housekeeping or workplace layout Process is not designed with employees in mind

Common causes: a) Poor workstation layout b) Isolated operations c) Shared tools d) Fatigue e) Workstation congestion

Processing 1. Doing more than is necessary to produce an effectively functioning product 2. Extra setup steps, over-specification of the process, extra processing steps Common causes: a) Lack of standard work or processes b) Equipment over designed c) Process not updated with technology changes d) Lack of effective problem solving

Defects / Quality 1. 2. 3. 4.

Defective or scrap materials Cost of inspecting defects Responding to customer complaints Rework or re-inspection of questionable materials

Common causes: a) Emphasis on downstream inspection; questionable material passed on b) Lack of standard work c) Material handling (transportation) d) Process design/equipment

Waiting 1. Operator waiting for machines to run or cycle 2. Machine waiting for operator 3. Waiting for parts, instructions, approval, information, maintenance, decisions. Common causes: a) Mismatched production rates b) Poor layout c) Machine breakdowns d) Insufficiently staffed

People’s Skills 1. Employees are seen as a source of labor only, not seen as true process experts 2. People are told what to do, and asked not to think 3. Employees are not involved in finding solutions, opportunities to improve our process are missed Common causes: a) Management does not involve employees in problem solving b) Narrowly defined jobs and expectations c) Old school management, worker relationships