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The 8 Wastes You Want to Avoid in Manufacturing

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Becoming a lean manufacturer is putting efforts to maximize quality by systematically eliminate defects during the production process. Inspired by Toyota's Production System (TPS), top manufacturers use technology to help them achieve that goal towards excellence in manufacturing. VKS is the #1 work instruction solution that's designed to efficiently reduce wastes and make you earn more revenue.

Dealing with wastes?
Let VKS help you!
Try one of these easy steps:
Book online: https://goo.gl/LG6SLf
Call us: 1-855-201-4656
Email us: info@vksapp.com

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Digital Work Instructions for Smart Factories

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The 8 Wastes You Want to Avoid in Manufacturing

  1. 1. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES By Berenice Mengo Online Marketing Specialist Visual Knowledge Share (VKS) Ltd The 8 Wastes You Want to Avoid in Manufacturing
  2. 2. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Welcome to the Fourth Industrial Revolution! Commonly referred to as Industry 4.0, the current industrial revolution attempts to reach nothing less than perfection in manufacturing. This might sound unrealistic but today’s smart factories are experiencing unprecedented levels of productivity, thanks to technology.
  3. 3. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES It is now a matter of survival to stay competitive in markets where quality is more valued than cheap prices. The Zero-Defect Mentality and Lean Manufacturing are examples of the ongoing quest towards excellence in manufacturing. QUALITY CHEAP PRICE
  4. 4. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Origin of the 8 Wastes The 8 Wastes are well-known among lean manufacturers. Inspired by the Toyota Production System (TPS), Lean manufacturing is a systematic method for the elimination of waste within a manufacturing system.
  5. 5. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Lean manufacturing implies minimizing defects, if not eliminating them completely. 8 specific wastes have been identified and the acronym DOWNTIME helps in memorizing them: Defects, Overproduction, Waiting, Non-Utilized Talent, Transportation, Inventory, Motion, and Extra-Processing. Defects Overproduction Waiting Non-Utilized Talent Transportation Inventory Motion Extra-Processing 8 specific wastes
  6. 6. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Defects Defects are the effort created by inaccurate information, waste and rework. Unfitted to a customer’s standard, defects make companies waste the time and material invested in producing that good. Moreover, you spend more time and money to process it again. Finally, business relationships with valuable clients may be jeopardized. That’s a lot of risk to deal with. Eliminating defects becomes a top priority in order to sustain viable businesses.
  7. 7. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Overproduction Production overflow generates unnecessary goods at inefficient times. The result is that companies spend time manufacturing goods that may not be sold, and one has to store and maintain them. Those enterprises end up bargaining their products, and this is not always a successful business model. Today’s smart factories produce goods according to the customer’s needs so that every manufactured good is already sold. Time left is used to train employees, maintain the facility, and for continuous improvement projects.
  8. 8. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Waiting Waiting time is wasted time. This is usually one of the easiest wastes to fix and one that can generate valuable benefits. If your work depends on the previous step to be completed by another resource, and the situation is causing unused time, then your process or maybe somebody in the production line isn’t efficient enough. Efficiency in time management is key for successful operations.
  9. 9. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Non-Utilized Talent Companies today realize that happy employees are their most valuable asset. Underutilized skills may lead to a high turnover rate or generate staff’s demotivation. It is important to encourage employees uniqueness and creativity, not by overexploiting them, but by making the best out of them. You never know, one of your employees may have a great idea that can benefit your company! Encouraging your employees regularly is less expensive than frequently hiring and training new ones.
  10. 10. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Transportation When you have to deliver physical goods, transportation is unavoidable. Inefficient logistics in transportation can lead to waste when there are pointless movements of goods and materials. One innovative way may be to produce the goods directly into the customer’s facilities if this is an option. Transportation is then limited to very few movements. Optimizing transportation also implies making the information surrounding the transportation the most fluent possible, as it can have a significant impact on the process.
  11. 11. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Inventory This is the most visible and maybe the worst of all wastes because it leads to several others. Extra products and materials that are not being processed are a direct consequence of overproduction. Inventory also leads to waiting, defects as products may expire, and extra-processing.
  12. 12. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Inventory Furthermore, inventory needs to be stored somewhere. If not stored correctly, it can be damaged or become a health and safety hazard. The ideal would be to have no inventory at all, but the reality makes that waste almost impossible to eliminate completely. Optimized work methods are essential to reduce inventory.
  13. 13. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Motion This can be a waste if your personnel spend time doing unnecessary movements due to unclear work instructions, inefficient multi-level processes, and more. For example, shifting papers in a printed guidebook to find the correct work instruction is a waste of time when you can simply upload the visual instructions by scanning the correct barcode.
  14. 14. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Extra-Processing Extra-processing occurs when there are inefficient processes in your workflow. Other wastes might be involved such as overproduction, inventory or defect. As an example, reworking a product is a waste when the good could have been successfully made in the first place. Clear and relevant work instructions help hit the target the first time.
  15. 15. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Extra-Processing Extra-processing is also a waste when efforts are made to deliver goods of a higher quality than expected by the customer. Expensive quality and productivity failures can refrain manufacturers from gaining their return on investment.
  16. 16. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES VKS is the solution! Visual Knowledge Share (VKS) is a visual work instruction software that helps companies increase their productivity, quality, and profitability. In addition to visually displaying your best practices in a user-friendly interface, VKS monitors performance within your factory, giving you live reports and traceability data to better control your production. In force in over 30 countries, VKS is helping customers dramatically minimize wastes as well as meeting their business goals!
  17. 17. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Dealing with wastes? Let VKS help you! BOOKA FREE DEMO TODAY! Try one of these easy steps: Book online: vksapp.com/services Call us: 1-855-201-4656 Email us: info@vksapp.com
  18. 18. V I S U A L K N O W L E D G E S H A R E DIGITAL WORK INSTRUCTIONS FOR SMART FACTORIES Learn more in our other Slideshares!

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