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The Seven Forms of Waste

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The Seven Forms of Waste - PowerPoint PPT Presentation


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The Seven Forms of Waste. Continuous Improvement focuses on the identification and elimination of the 7 forms of waste: Overproduction Inventory Unnecessary Motion Transportation Waiting Over Processing Defects / Repair / Rework. 1. Over Production.

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The Seven Forms of Waste

Continuous Improvement focuses on the identification and elimination of the 7 forms of waste:

  • Overproduction
  • Inventory
  • Unnecessary Motion
  • Transportation
  • Waiting
  • Over Processing
  • Defects / Repair / Rework
slide2
1. Over Production
  • Producing products or materials before they are needed.
  • Overproduction is the worst form of waste because it is the root cause of many other wastes.
  • Results of Over Production:
    • Products being produced in excess quantities
    • Products being made before customers need them
    • Excess Inventory
    • Excess Transportation
    • Hides available capacity
  • Caused by:
    • Working ahead of customer (internal/external) or process requirements
slide3
Waste Of Overproduction : Example

OPERATOR SHOULD BE IN THIS STATION (ST 16) BUT IS WORKING AHEAD IN ST 15

slide4
2. Inventory
  • Excess inventory is not directly required for current customer orders.
  • Results of Excess Inventory:
    • requires space
    • costs money and ties up capital
    • search and transport damage
    • hides defects
    • excess WIP and finished out-of-date product
    • Increased deterioration
  • Caused by:
    • Working ahead of build requirements
    • High WIP standards
    • No WIP standards
    • Lack of JIT/Pull system
slide5
Excess Inventory: Example

STANDARD SET AT 4 HIGH X 3 DEEP

PART BIN STACKED 6 HIGH

slide6
3. Motion
  • Unnecessary movement in a process.
  • Some Results of Motion:
    • unnecessary walking
    • poor ergonomic conditions
    • part transfer
    • reaching and stopping and walking to locate/ pick up parts/tools
  • Caused by:
    • poor parts placement
    • poor process flow
    • poor work station layout
slide7
Waste of Motion: Example

TEAM MEMBER IN PAINT SHOP ATTEMPTING TO UNTANGLE HOSES TO THE BACK-UP GUNS IN THE TOP COAT BOOTH.

slide8
4. Transportation
  • The unnecessary movement of materials
  • Results of Transportation:
    • Loss of traceability
    • Damaged goods
    • Increased Lead Time
    • Excess Costs
    • Storage space
  • Caused by:
    • Poor parts storage
    • Poor Work area layouts
    • Working ahead of build requirements
    • Lack of JIT/ Pull system
slide9
Waste of Transportation: Example

BODY SHOP CONVEYANCE DELIVERS AMS BRACKETS TO TABLE ON THE FLOOR

BODY SHOP T/M CARRIES PARTS TO RACK LINESIDE.

slide10
5. Waiting
  • Periods of inactivity in a downstream process that occur because an upstream activity does not deliver on time.
  • Results of Waiting:
    • Over Production
    • Over Processing
    • Idle resources
    • Non-Value added work
  • Caused by:
    • Line stops
    • Waiting for Material
    • Repair/Maintenance
    • Waiting for equipment to process
    • Missing tools
    • Non- “Full” work process
slide11
Waste of Waiting: Example

TEAM MEMBER WAITING ON BODY

IN ST. 3900. ROBOTS IN ST. 2400

WENT DOWN CAUSING DOWNTIME

slide12
6. Over Processing
  • Producing more or better than the customer requires.
  • Results of Over Processing:
    • Increased Processing Time
    • Costs
    • Incorrect process/equipment
  • Caused by:
    • Refining the product in ways or areas not
    • important to the customer
    • Wait Time
    • Unclear Quality Standards
slide13
Waste of Over Processing: Example

BODY SHOP T/M SANDING DOOR THAT HAD NO DEFECTS

slide14
7. Defects/Repair/Rework
  • Products or aspects of the production processes that do not conform to specifications or to the customer’s expectations.
  • Results of Defects/Repair/Rework:
    • Customer Dissatisfaction
    • Non-Value added work
    • Extra costs
    • Extra space
    • Extra inspections/checks
  • Caused by:
    • Scrapped parts
    • Wrong or defective tools or machines
    • Wrong or missing processes
    • Poor Problem Solving
    • Unclear Standards
slide15
Waste of Repair: Example

PAINT SHOP T/M MAKING REPAIR IN SPOT REPAIR BOOTH.

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