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  1. 1. MUDA<br />Muda is a japanese word, which means waste, where waste is any activity that does not add value. Reducing or eliminating muda is, of course, one of the fundamental objectives of any quality-oriented person. <br />TaichiOhno of Toyota identified what are called the seven wastes or seven mudas, being the most common form of muda found: <br />
  2. 2. Waste from overproduction<br />Waste of time in waiting <br />Transportation waste <br />Processing waste <br />Inventory waste <br />Waste of motion <br />Waste from product defects <br />
  3. 3. 1.Waste from overproduction <br />Which leads to excess inventory, paperwork, handling, storage, space, interest charges, machinery, defects, people and overhead. <br />It is often difficult to see this waste as everyone seems busy. <br />Unnecessary production to show higher machine utilization (or lower manufacturing cost)<br />Stategies to eliminate :-<br />Strong production planning and control<br />Production according to custmer schedule<br />Firm delivery requirement from markting.<br />
  4. 4. 2.Waste of time in waiting :-<br />Its occurs when worker or machine is not performing its job.<br />People may be waiting for parts or instructions. <br />Mostly they are waiting for one another, which often happens because they have non-aligned objectives. <br />The talent of employes also wasted.<br />Tools to identify :-<br />Kaizen<br />Method study<br />
  5. 5. 3.Transportation waste :-<br />It is highly visible form of waste unnecessary transportation create the need for more storage space,moreequp., and workers.<br />Poor layouts lead to things being moved multiple times. <br />If things are not well place, they can be hard to find. <br />It can aggravate alignment of processes. <br />Stategies to eliminate :-<br />Store material as close to the point of use as possible<br />Avoide transportation over long distance.<br />Avoid over production. <br />
  6. 6. 4.Waste from product defects:-<br />Defects imply rework or reject. Research confirms that 20 to 30% of manufacturing company’s gross revenues are spent on correcting mistake.<br />Defects cause rework, confusion and upset a synchronized set of processes. <br />Loss of customer<br />Loss of future business<br />Causes of defects:-<br />Incorrect product design<br />Defective materials<br />Poorly trained employees<br />
  7. 7. Stategies to eliminate :-<br />Design reviews<br />Training to employees<br />Mantenance of machines and equipment.<br />
  8. 8. 5.Waste of motion <br />A worker while performing a task makes use of a number of motions.some of these motion-<br />Are unnecessary and can be eliminated<br />Can be combined by changing their sequence.<br />Can be performed efficiently by other members of the body.<br />Stategies to eliminate :-<br />Motion economy principal<br />Effective suparvision<br />
  9. 9. 6.Inventory waste :-<br />Inventory comprises of finished goods semi-finished products or parts and supplies.Excess inventory is a real waste as it dose not add value but add to the cost by-<br />Occupying space<br />Requiring additional equipment and facilities such as storage racks,cupboards etc.<br />Insurancing stock <br />Stategies to eliminate :-<br />Dispose off obsolete material to save space and to avoid confusion.<br />Do not produce items ahead of custmer’s delivery requirements.<br />Do not manufacture products in excess of custmer’s requirements.<br />
  10. 10. 7.Processing waste :-<br />Processing cost of a product is mainly decided by conversion process,combination of mechanical and chemical operations and supports activities required to produce goods and services.<br />Additional effort may be required in an inefficient process<br />Causes of MUDA of processing:-<br />Poor allocation of work to men<br />Failure to identify and use of most effective method<br />Over production<br />
  11. 11. Tools to eliminate:-<br />Method study<br />Simplification<br />Kaizen<br />Muda in office:-<br />Muda can also be found in support function such as engineering,planning,marketing,purchase,stores,a/c and HRM etc.<br />Examples of muda in office<br />Waiting the people at meeting<br />Making unproductive phone calls<br />Unnessary copies of documents<br />Letterheads printed in excess of requirements.<br />
  12. 12. Tools to eliminate:-<br />Work Simplification<br />5-s technique for office<br />A simplified view of muda is: <br />Wasting time. <br />Wasting a consumable resource, such as materials. <br />Causing dis-satisfaction (including incomplete satisfaction).<br />Muda is one of the '3Ms': muda, or waste, mura, meaning irregular, uneven or inconsistent, and muri, meaning un-reasonable or excessive strain. <br />The acronym 'DOT WIMP' can be used to remember Muda wastes (Defects, Overproduction, Transportation, Waiting, Inventory, Motion, Processing).<br />A variant on Mudas is sometimes called the '8 Wastes of Lean', changing 'processing' to 'over-processing', and adding under-use of skills. This has the acronym 'TIM WOODS' (Transport, Inventory, Motion, Waiting, Over-production, Over-processing, Defects, Skills).<br />
  13. 13. Thank you<br />