MUDA MURA MURI
MANIKANDAN.C CINISH P ABRAHAM VIPUL KOTADIA
Lean Management or quot;Leanquot; is the optimal way of managing through the
removal of waste and implementing flow.
It is renowned for its focus on reduction of the original process wastes in
order to improve overall customer value.
In simple term, more value with less work.
Lean manufacturing is derived mostly from the Toyota Production System
(TPS) Identified as quot;Leanquot; only after 1990s.
Goal is to eliminate the waste from the process.
TOYOTA PRODUCTION SYSTEM
Make what the customer needs, when it is needed, in the right
Separate machine work from human work and fully utilize both
Build quality into the process and prevent errors from happening
Reduce lead-times to allow for rapid, flexible scheduling
Produce a high mix of low volume products efficiently
LEAN PRODUCTION - TPS
Main goals of Toyota Production System (TPS) are to eliminate:
Overburden or stress in the system (muri)
Goal is to design a process that runs smoothly, can flex without stress, and
Using TPS, Toyota was able to reduce lead-time and cost, while improving
Eliminating 3 M
(Strain / Over burden)
MUDA is the Waste, work that does not add any value to the product
Process-1 V Process-2 V Process-3 V Process-4 V
W W W W
V: Value added product/services
W: Wasteful product / practices/services that does not add value
Economic Value of Waste
Every business activity absorbs
resources and every resource has
Every waste has a cost, and that
is direct loss to the company.
Economic value of waste in a
process industry are in the range
of 10 -35% of annual turnover
7 Seven MUDA [Wastes]
Waiting for work and materials
Inventories / Unnecessary WIP
MUDA of Motion
Movement that does not add value
Searching for files
Extra clicks or key strokes
Clearing away files on the desk
Looking through manuals and catalogs
MUDA of Waiting
Idle time created when material, information, people or
equipment is not ready.
The system to come back
A handed off file to come back
MUDA of Transport
I am more expensive
since raw material is
coming from a far
MUDA of Transport
Movement of information that does not add
Carrying documents to and fro from shared
Taking files to another person
Going to get signatures
MUDA of Over
Generating more information than the customer needs
More information than the customer needs
Creating reports no one reads
Making extra copies
More information than the next process needs
MUDA of Process
1. Using more expensive
equipment or tools where
simpler ones would suffice.
2. Having meetings that are not
3. Having people at meetings
that are not required.
4. Agenda points, not to be
Efforts that create no value from the customer
Repeated manual entry of data
Duplicity of work
Use of outdated standard forms
Use of inappropriate software
More information, project, material on hand than
the customer needs right now:
Files waiting to be worked on
E-mails waiting to be read
Unused records in the database
Work that contains errors, rework, mistakes or
lacks something necessary:
Data entry error
How to eliminate?
Find the Root Cause
- Asking ‘WHY’ for 5 times
- 5W 1H
5 W 1 H of MUDA
T h e Fiv e W s an d T h e O n e H
W ho W hat W here
1. W ho do es it? 1. W hat to do ? 1. W here to do it?
2. W ho is do ing it ? 2. W hat is be ing do ne ? 2. W here is it do ne?
3. W ho sho u ld be do ing it ? 3. W hat sho u ld be do ne ? 3. W here sho u ld it be do ne ?
4. W ho e lse ca n do it? 4. W hat e lse ca n be do ne ? 4. W here e lse ca n it be do ne ?
5. W ho e lse sho u ld do it? 5. W hat e lse sho u ld be do ne ? 5. W here e lse sho u ld it be
6. W ho is do ing 3-M us? 6. W hat 3-M U s are be ing do ne ?
do ne? 6. W here are 3- M U s be ing
Muri is the overburden on equipment, facilities & people caused by
mura and muda.
This is in some respects on the opposite end of the spectrum of
Muri is pushing a machine or person beyond natural limits.
Overburdening people results in safety and quality problems.
Overburdening equipment causes breakdowns and defects
MURI = Physical Strain, Overbourden
Bend to work?
Repeat tiring action?
Placing of excessive demands on
M/Cs, Production equipment.
Muri is caused by the respect of unsuited standards
Mura is the variation in the operation of a process not
caused by the end customer.
It is the unevenness, unbalanced work on machines.
Mura results when employees are told to work like crazy
early in the morning only to stand around and do nothing
late in the day.
Result: Excess capacity allocation and increased cost.
Happens some places
Happens to some people
One side is ok; the other side is not ok
Uneven use of person or M/c.
Doesn’t happen by
It has to be