2. Mnemonic for memorizing the
“8 Wastes”
D = Defects
O = Overproduction
W = Waiting
N = Non-utilizing Talents
T = Transport
I = Inventory
M = Motion
E = Excess Processing
3. Defects
Producing defective products that require rework or disposal, leading
to added costs and reduced customer satisfaction.
Example: A company produces a batch of products that do not
meet quality standards and must be reworked or disposed of.
Solution: Process value mapping can help identify
areas where defects occur and can help eliminate
this waste by improving quality control processes
and implementing error-proofing techniques.
4. Overproduction
A company produces more products than their customers demand,
leading to a buildup of excess inventory. Overproduction ties up
capital and space, increases the risk of product damage or
obsolescence, and creates unnecessary storage costs.
Example: A company produces 1000 units of a product but
only needs 500 units for current demand. The excess 500 units
sit in inventory, tying up capital and storage space.
Solution: Process value mapping can help identify
areas where overproduction occurs and can help
eliminate this waste by adjusting production
schedules or optimizing inventory management.
5. Waiting
The delay between operations that leads to idle time and wasted
resources.
Example: A worker waits for a machine to finish a task before
they can begin their next task.
Solution: Using process value mapping, the company
can identify where waiting occurs and implement
strategies to reduce it, such as improving
communication between steps, optimizing the layout
of the production line, or adjusting the scheduling of
operations.
6. Non-utilizing talents
Underutilizing the knowledge, creativity, and skills of employees,
which can limit the organization's potential for innovation and
improvement.
Example: A company does not encourage employees to
suggest improvements to processes or provide feedback on
current practices.
Solution: Using process value mapping, the
company can identify where employee talent is
being underutilized and implement strategies like
gamification to improve employee engagement or
involving employees in problem-solving and
decision-making processes.
7. Transport
Moving materials or products unnecessarily, which can cause damage
and add to the cost of production.
Example: A company transports materials between multiple
warehouses, increasing the risk of damage and adding to
transportation costs.
Solution: Using process value mapping, the
company can identify where transportation waste
occurs and implement strategies to reduce it, such
as consolidating warehouses or optimizing the
routing of transportation.
8. Inventory
Excess inventory, which ties up capital and space, and can lead to
higher carrying costs.
Example: A company has an excess of raw materials that sit in
inventory for an extended period.
Solution: Process value mapping can help identify
areas where excess inventory occurs and can help
eliminate this waste by adjusting production
schedules or optimizing inventory management.
9. Motion
Unnecessary movement of people or equipment that can waste time
and energy.
Example: A worker walks back and forth between two
machines when they could have been arranged closer together.
Solution: Process value mapping can help identify
areas where motion wastes occur and can help
eliminate this waste by optimizing machine and
worker placement.
10. Excess Processing
Performing unnecessary operations or processing steps that do not
add value to the final product.
Example: A company performs unnecessary processing steps
that do not add value to the final product, such as additional
quality checks.
Solution: Using process value mapping, the
company can identify where unnecessary processing
occurs and implement strategies to eliminate it, such
as implementing more efficient quality control
measures or eliminating redundant processing steps.
11. CONCLUSION
In conclusion,
identifying and eliminating the
Eight Wastes through
Process Value Mapping
can help create
a more efficient and productive
production process, leading to
cost savings, improved quality,
and increased customer
satisfaction.
