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The Eight Wastes


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The Eight Wastes

  1. The 8 Forms of WASTE Finding Innovation Through TeamworkFinding Innovation Through Teamwork
  2. What is Waste? • Muda (Japanese word for waste) • More specifically, any object or activity that adds NO value to the expected outcome • Value is in the eyes of the CUSTOMER • Waste absorbs both time and money, causing inefficiency • 7 forms of waste originally identified by Taiichi Ohno (1912-1990)Finding Innovation Through Teamwork
  3. Muda, Mura & MuriFinding Innovation Through Teamwork
  4. The Value StreamFinding Innovation Through Teamwork
  5. Finding Innovation Through Teamwork
  6. Over Production • Making too much • Producing too early • Making it “just in case” • Considered the most serious of the wastes • Examples? – Making too many copies – Double entering/writing anything – Making widgets early and having them sit on the production floor.Finding Innovation Through Teamwork
  7. Finding Innovation Through Teamwork
  8. Waiting • When time is not used effectively • Anytime materials or components are not moving or adding value • Examples: – Waiting for people – Documents that sit, waiting for a signature – WIP waiting for the next step in a process – Late deliveries (supplies)Finding Innovation Through Teamwork
  9. Finding Innovation Through Teamwork
  10. Transporting • Movement of materials within a factory • The number of movements = the number of opportunities to damage and/or deteriorate • Automate transportation whenever possible • In Japan… AGVs, material delivered to where it is needed (vehicle dashboards)Finding Innovation Through Teamwork
  11. Finding Innovation Through Teamwork
  12. Inappropriate (Over) Processing • Machines and/or processes that are not capable of quality output • Using the wrong tool for the job – Cracking a nut with a sledge hammer – Cutting down trees with a dull axeFinding Innovation Through Teamwork
  13. Finding Innovation Through Teamwork
  14. Unnecessary Inventory • The “enemy” of quality and productivity • Inventory exceeding specified quantity limit – Some degree of buffer inventory can be acceptable when supplier lead times are long and can not be changed. – Kanban should be implemented, pull • Negative impact on cash flow • Think about your office supply room… – Paper and tonerFinding Innovation Through Teamwork
  15. Finding Innovation Through Teamwork
  16. Unnecessary Motion • Refers the ergonomics of the workplace • Too much bending, turning, reaching, walking, or moving to do the job (ie. wrench > air ratchet > quick connect) • Everything you need to perform a task should be within arms reach and in front of youFinding Innovation Through Teamwork
  17. Finding Innovation Through Teamwork
  18. Defects • Producing something that does not meet the customer’s expectation(s). • Internal and external failures • Scrap, rework, less than perfect yield, complaints, missing info, etc… • Generally, the form of waste that gets the most attention. – Why?Finding Innovation Through Teamwork
  19. #8 Unused or Misused Skills / Talent Not taking full advantage of peoples skills, knowledge and abilities…Finding Innovation Through Teamwork way we’ve always done it…” “But that’s the
  20. Unused or Misused Skills/Talents • Not going to the gemba • Not involving the stakeholders in problem solving and root cause analysis • Preventing people from reaching their potential by utilizing their abilities • Product of micromanaging • Your front-line staff are the ones charged with creating the value for your customers. Therefore, they need to be engaged.Finding Innovation Through Teamwork
  21. Waste Elimination ToolFinding Innovation Through Teamwork
  22. Finding Innovation Through Teamwork