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Muda, Mura & Muri

Why elimination of the "3 mu" is at
       the heart of kaizen?

       Anand Subramaniam
“The greatest wastes are unused talents and
               untried ideas..”

                              - Unknown Source




                                             2
3 MU

        Muri                    Muda                   Mura




                                                • Unevenness
• Unreasonableness       • Unusefulness
                                                • Shifts in demand
• A process, system,     • An activity within
                                                  or delivery that
  or facility designed     a process that
                                                  lead to a service
  beyond the physical      does not add
                                                  or support
  capacities of            value, from the
                                                  process being
  employees /              perspective of the
                                                  sped up or slowed
  equipment                customer
                                                  down (unsteady)



                                                                      3
Taiichi Ohno


 The Father of Toyota
  Production System,
  JIT, and Lean
  Manufacturing

 Identified the 7 types
  of Muda


                                 4
What is Waste ?


Waste is “anything other than the minimum
 amount of equipment, materials, parts,
  space, and worker’s time which are
 absolutely essential to add value to the
                 product.”

                               Shoichiro Toyoda
                               President, Toyota

                                               5
Why Look @ Waste Reduction




                             6
Waste - Root Causes
   WOMBAT = Waste of Money, Brains And Time




Inflexibility               Variability          Redundancy




                 Schedule                 Task


                                                              7
Waste Types
                    Transport
      Motion                     Rework



Overproducing                         Inventory
                   Waste Types

  Overprocessing
                     Intellect



                                              8
Waste Types (Contd.)

 Transport
   Movement of product that does not add value


 Inventory
   Ties up capital, takes valuable space,
    requires moving, difficulty in finding material,
    obsolescence, losses due to damage
   Reduces customer responsiveness and
    multiplies quality problems
                                                       9
Waste Types (Contd.)
 Motion
    Movement of people that does not add value


 Waiting
    Idle time created when material, information, people,
     or equipment is not ready


 Under utilising talent
    Under utilising employees’ potential (their creative
     ideas)
                                                             10
Waste Types (Contd.)

 Over processing
   Effort that adds no value from the customer’s
    viewpoint


 Defect
   Work that contains errors, rework, mistakes or
    lacks something necessary
   Creating / correcting defects robs resources,
    “chokes” flow
                                                    11
Waste Types (Contd.)

 Overproduction
   Producing more than the customer needs
    right now
   Consumes valuable resources not
    immediately needed
   Hides other process problems (bad quality,
    poor scheduling, poor delivery)
   Builds inventory not needed


                                                 12
Waste Hierarchy
 By Reducing waste,
  we minimise the load
  on landfill and
  transport

 By sorting our wastes,
  we make it easier to
  Reuse and Recycle



                                13
Lean Tool to remove Waste
Input       Waste                 Lean Tool
Man          Motion               Standard Work
             Walking              5 S’s
             Waiting              3P (Product Preparation
             Searching             Process)

Machine      Motion               3P
             Setup/Change over    Setup Reduction
             Breakdown            TPM

Material     Inventory            Pull System

Method       Batch production     Flow Production
             Transportation       One Piece Flow

                                                              14
“It has been my observation that most
  people get ahead during the time that
             others waste.”

                                - Henry Ford




                                          15
Good Luck
http://www.linkedin.com/in/anandsubramaniam




                                              16

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3 MU

  • 1. Muda, Mura & Muri Why elimination of the "3 mu" is at the heart of kaizen? Anand Subramaniam
  • 2. “The greatest wastes are unused talents and untried ideas..” - Unknown Source 2
  • 3. 3 MU Muri Muda Mura • Unevenness • Unreasonableness • Unusefulness • Shifts in demand • A process, system, • An activity within or delivery that or facility designed a process that lead to a service beyond the physical does not add or support capacities of value, from the process being employees / perspective of the sped up or slowed equipment customer down (unsteady) 3
  • 4. Taiichi Ohno  The Father of Toyota Production System, JIT, and Lean Manufacturing  Identified the 7 types of Muda 4
  • 5. What is Waste ? Waste is “anything other than the minimum amount of equipment, materials, parts, space, and worker’s time which are absolutely essential to add value to the product.” Shoichiro Toyoda President, Toyota 5
  • 6. Why Look @ Waste Reduction 6
  • 7. Waste - Root Causes WOMBAT = Waste of Money, Brains And Time Inflexibility Variability Redundancy Schedule Task 7
  • 8. Waste Types Transport Motion Rework Overproducing Inventory Waste Types Overprocessing Intellect 8
  • 9. Waste Types (Contd.)  Transport  Movement of product that does not add value  Inventory  Ties up capital, takes valuable space, requires moving, difficulty in finding material, obsolescence, losses due to damage  Reduces customer responsiveness and multiplies quality problems 9
  • 10. Waste Types (Contd.)  Motion  Movement of people that does not add value  Waiting  Idle time created when material, information, people, or equipment is not ready  Under utilising talent  Under utilising employees’ potential (their creative ideas) 10
  • 11. Waste Types (Contd.)  Over processing  Effort that adds no value from the customer’s viewpoint  Defect  Work that contains errors, rework, mistakes or lacks something necessary  Creating / correcting defects robs resources, “chokes” flow 11
  • 12. Waste Types (Contd.)  Overproduction  Producing more than the customer needs right now  Consumes valuable resources not immediately needed  Hides other process problems (bad quality, poor scheduling, poor delivery)  Builds inventory not needed 12
  • 13. Waste Hierarchy  By Reducing waste, we minimise the load on landfill and transport  By sorting our wastes, we make it easier to Reuse and Recycle 13
  • 14. Lean Tool to remove Waste Input Waste Lean Tool Man  Motion  Standard Work  Walking  5 S’s  Waiting  3P (Product Preparation  Searching Process) Machine  Motion  3P  Setup/Change over  Setup Reduction  Breakdown  TPM Material  Inventory  Pull System Method  Batch production  Flow Production  Transportation  One Piece Flow 14
  • 15. “It has been my observation that most people get ahead during the time that others waste.” - Henry Ford 15