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© Operational Excellence Consulting. All rights reserved.
This presentation is a collection of specific examples of the ei...
© Operational Excellence Consulting. All rights reserved. 2
Contents
1. Lean Wastes in Manufacturing
2. Lean Wastes in Pro...
© Operational Excellence Consulting. All rights reserved.
Lean Wastes in Manufacturing
1
© Operational Excellence Consulting. All rights reserved. 4
Lean Wastes in Manufacturing
Over-production
Producing sooner,...
© Operational Excellence Consulting. All rights reserved. 5
Lean Wastes in Manufacturing
• Inventory stockpiling or buildi...
© Operational Excellence Consulting. All rights reserved. 6
Lean Wastes in Manufacturing
• Waiting for materials or equipm...
© Operational Excellence Consulting. All rights reserved. 7
Lean Wastes in Manufacturing
• Ordering parts or products from...
© Operational Excellence Consulting. All rights reserved. 8
Lean Wastes in Manufacturing
• Providing higher quality than i...
© Operational Excellence Consulting. All rights reserved.
Lean Wastes in Healthcare
2
© Operational Excellence Consulting. All rights reserved. 10
Lean Wastes in Healthcare
Over-production
Producing more, soo...
© Operational Excellence Consulting. All rights reserved. 11
Lean Wastes in Healthcare
• Expired test reagents
• Expired d...
© Operational Excellence Consulting. All rights reserved. 12
Lean Wastes in Healthcare
• Patients waiting due to schedule
...
© Operational Excellence Consulting. All rights reserved. 13
Lean Wastes in Healthcare
Defects • Misdiagnoses that lead to...
© Operational Excellence Consulting. All rights reserved.
Lean Wastes in Financial
Services
3
© Operational Excellence Consulting. All rights reserved. 15
Lean Wastes in Financial Services
• Creating reports that no ...
© Operational Excellence Consulting. All rights reserved. 16
Lean Wastes in Financial Services
• Waiting to be served
• Wa...
© Operational Excellence Consulting. All rights reserved. 17
Lean Wastes in Financial Services
Intellect • Narrowly define...
© Operational Excellence Consulting. All rights reserved.
Lean Wastes in IT Services
4
© Operational Excellence Consulting. All rights reserved. 19
Lean Wastes in IT Services
• Each account having a customized...
© Operational Excellence Consulting. All rights reserved. 20
Lean Wastes in IT Services
• Handover of tasks from developer...
© Operational Excellence Consulting. All rights reserved. 21
Lean Wastes in IT Services
Defects • Inadequate testing befor...
© Operational Excellence Consulting. All rights reserved.
Lean Wastes in Government
(Public Services)
5
© Operational Excellence Consulting. All rights reserved. 23
Lean Wastes in Government (Public Services)
• Waiting to be s...
© Operational Excellence Consulting. All rights reserved. 24
Lean Wastes in Government (Public Services)
• Traveling from ...
© Operational Excellence Consulting. All rights reserved. 25
Lean Wastes in Government (Public Services)
• Reaching, bendi...
© Operational Excellence Consulting. All rights reserved.
Lean Wastes in Office
6
© Operational Excellence Consulting. All rights reserved. 27
Lean Wastes in Office
• Shelves of unused office supplies
• S...
© Operational Excellence Consulting. All rights reserved. 28
Lean Wastes in Office
• Reaching, bending or unnecessary moti...
© Operational Excellence Consulting. All rights reserved. 29
Lean Wastes in Office
Intellect • Employees do not have the o...
© Operational Excellence Consulting. All rights reserved.
Lean Wastes in Product
Development
7
© Operational Excellence Consulting. All rights reserved. 31
Lean Wastes in Product Development
• Working with incomplete ...
© Operational Excellence Consulting. All rights reserved. 32
Lean Wastes in Product Development
• Product designs or proce...
© Operational Excellence Consulting. All rights reserved.
About
Operational Excellence Consulting
© Operational Excellence Consulting. All rights reserved. 34
About Operational Excellence
Consulting
• Operational Excelle...
© Operational Excellence Consulting. All rights reserved.
To download this presentation,
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www.oeconsult...
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Eight Wastes of Lean (by Industry or Function) by Operational Excellence Consulting

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This presentation is a collection of specific examples of the eight wastes of Lean, organized according to industry or function. They include: Manufacturing, Healthcare, Financial Services, IT Services, Government (Public Sector) and Office (Administrative Functions).

These slides are useful for trainers and consultants who are looking to supplement their own presentations using examples that are specific to their client's industry. No more wasting time searching for these materials in the internet!

CONTENTS:

1. Lean Wastes in Manufacturing
2. Lean Wastes in Healthcare
3. Lean Wastes in Financial Services
4. Lean Wastes in IT Services
5. Lean Wastes in Government (Public Services)
6. Lean Wastes in Office

To download this complete presentation, visit: http://www.oeconsulting.com.sg

Published in: Business

Eight Wastes of Lean (by Industry or Function) by Operational Excellence Consulting

  1. 1. © Operational Excellence Consulting. All rights reserved. This presentation is a collection of specific examples of the eight wastes of Lean, organized according to industry or function. They include: Manufacturing, Product Development, Healthcare, Financial Services, IT Services, Government (Public Sector) and Office. Eight Wastes of Lean by Industry or Function Examples of Eight Wastes of Lean Organized by Industry or Function
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Contents 1. Lean Wastes in Manufacturing 2. Lean Wastes in Product Development 3. Lean Wastes in Healthcare 4. Lean Wastes in Financial Services 5. Lean Wastes in IT Services 6. Lean Wastes in Government (Public Services) 7. Lean Wastes in Office NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: http://www.oeconsulting.com.sg
  3. 3. © Operational Excellence Consulting. All rights reserved. Lean Wastes in Manufacturing 1
  4. 4. © Operational Excellence Consulting. All rights reserved. 4 Lean Wastes in Manufacturing Over-production Producing sooner, faster or in greater quantities than customer demand Inventory Raw material, WIP or finished goods which is not having value added to it Transportation Unnecessary movement of people or parts between processes Defects Work not done right the first time such as scrap and rework Over-processing Processing beyond the standard required by the customer Motion Unnecessary movement of people, parts or machines within a process Intellect Not using employees full intellectual contribution Waiting People or parts that wait for a work cycle to be completed Waste
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 Lean Wastes in Manufacturing • Inventory stockpiling or building ahead of schedule • Purchasing materials before they are needed • Producing more to “make up” for production losses such as defects • Delivering more than what was ordered • Unbalanced material flow • Exceeding scope of agreement Over-Production Waste of Over-Production
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 Lean Wastes in Manufacturing • Waiting for materials or equipment to be delivered • Person waiting for machine; machine waiting for person; person waiting for person • Waiting due to quality issues • Waiting for breakdown to be resolved • Waiting for instructions, approvals, information or decisions • Seeking clarifications (due to unclear communications) • Stockouts Waiting Waste of Waiting
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 Lean Wastes in Manufacturing • Ordering parts or products from distant suppliers when closer options are available • Sending unsold products from the store back to the warehouse • Moving containers of materials • Carrying WIP over long distances • Moving in and out of storage areas or in between processes • Multiple storage locations • Sub-optimal dispatch or routing Transportation Waste of Transportation
  8. 8. © Operational Excellence Consulting. All rights reserved. 8 Lean Wastes in Manufacturing • Providing higher quality than is necessary • Repeating the same or similar steps (redundancy) • Band-aid reactions to past quality problems • Removing coating or paint overspray from an unwanted area • Unnecessary part/system replacement • Excessive documentation • Redundant approvals (checkers checking on checkers) Over-Processing Waste of Over-Processing
  9. 9. © Operational Excellence Consulting. All rights reserved. Lean Wastes in Healthcare 2
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 Lean Wastes in Healthcare Over-production Producing more, sooner, or faster than required Inventory Storing excess drugs/supplies, including unnecessary equipment and resources Transportation Unnecessary movement of patients, specimens and supplies Defects Errors or corrections due to work not being done correctly Over-processing Putting more work into a process than required Motion Extra physical/mental motion that does not add value Intellect Not using employees full intellectual contribution Waiting Waiting for another person, process or equipment Waste
  11. 11. © Operational Excellence Consulting. All rights reserved. 11 Lean Wastes in Healthcare • Expired test reagents • Expired drugs • Excess drugs and supplies • Specimens waiting to be analyzed • Emails waiting to be read • Unused records in the database • Low use to equipment ratios (e.g. photocopiers, printers, etc.) Inventory Waste of Inventory
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 Lean Wastes in Healthcare • Patients waiting due to schedule exceeding capacity • Emergency room patients waiting for test results • Specimens waiting in batches for testing in the lab • Waiting for patients, beds, equipment, operating rooms, information, etc. • Seeking clarifications (due to unclear communications) • Equipment/System downtime • Out-of-stock drugs and supplies Waiting Waste of Waiting
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 Lean Wastes in Healthcare Defects • Misdiagnoses that lead to unnecessary tests or treatment • Mislabeled patient specimens • Wrong medication delivered to patient • Performing tests on an instrument that is experiencing a QC violation • Data entry errors, mistakes or rework • Missing information, missed specifications, or lost records • Lost or damaged drugs and supplies Waste of Defects
  14. 14. © Operational Excellence Consulting. All rights reserved. Lean Wastes in Financial Services 3
  15. 15. © Operational Excellence Consulting. All rights reserved. 15 Lean Wastes in Financial Services • Creating reports that no one needs or making extra copies • Duplicating computations of similar data • Endless consolidation of existing reports • Excess email messages • Performing unrequested work • Purchasing items before they are needed • Providing more information than the customer needs Over-Production Waste of Over-Production
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 Lean Wastes in Financial Services • Waiting to be served • Waiting for internet banking system to be restored • Waiting for the delivery of a financial product (e.g. new insurance policy) or service • Waiting for information from other departments • Seeking clarifications on product promotions • Equipment/System downtime Waiting Waste of Waiting
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 Lean Wastes in Financial Services Intellect • Narrowly defined jobs and expectations • Not engaging or listening to employees in finding solutions • Mismatched work functions with skill sets • Lack of information or best practice sharing across the organization • Lack of teamwork • Poor management Waste of Intellect
  18. 18. © Operational Excellence Consulting. All rights reserved. Lean Wastes in IT Services 4
  19. 19. © Operational Excellence Consulting. All rights reserved. 19 Lean Wastes in IT Services • Each account having a customized solution • Backlog such as tickets and feature requests waiting to be worked on • Excessive requirements churn • Excess servers and other IT equipment • Obsolete databases, files and folders • Excess materials and information Inventory Waste of Inventory
  20. 20. © Operational Excellence Consulting. All rights reserved. 20 Lean Wastes in IT Services • Handover of tasks from developer to tester • Insufficient use of remote diagnosis • Sub-optimal dispatch and routing • Report routing • Taking files to another person, or going to get signatures • Poor office layouts • Double or triple handling • Retrieving or storing files Transportation Waste of Transportation
  21. 21. © Operational Excellence Consulting. All rights reserved. 21 Lean Wastes in IT Services Defects • Inadequate testing before production • Architecture group designs system specifications without checking for implementability • Lack of standards for naming, coding GUI interfaces, etc. • Data entry errors, mistakes or rework • Missing information, missed specifications, or lost records • Incorrect schedules and information Waste of Defects
  22. 22. © Operational Excellence Consulting. All rights reserved. Lean Wastes in Government (Public Services) 5
  23. 23. © Operational Excellence Consulting. All rights reserved. 23 Lean Wastes in Government (Public Services) • Waiting to be served • Waiting for information from the applicant • Waiting for information from other departments • Waiting for colleagues who are absent for other reasons • Seeking clarifications (due to unclear communications) • Equipment/System downtime Waiting Waste of Waiting
  24. 24. © Operational Excellence Consulting. All rights reserved. 24 Lean Wastes in Government (Public Services) • Traveling from counter to counter • Data transport: The route an application makes past all sorts of officials down the chain • Report routing • Retrieving or storing documents • Taking files to another person, or going to get signatures • Sub-optimal dispatch • Double or triple handling Transportation Waste of Transportation
  25. 25. © Operational Excellence Consulting. All rights reserved. 25 Lean Wastes in Government (Public Services) • Reaching, bending or unnecessary motion due to poor ergonomics and office layout • Walking to meeting room • Trips to printers and copiers • Searching for information in internet, intranet or shared folders • Searching for tools, files and supplies • Handling paperwork Motion Waste of Motion
  26. 26. © Operational Excellence Consulting. All rights reserved. Lean Wastes in Office 6
  27. 27. © Operational Excellence Consulting. All rights reserved. 27 Lean Wastes in Office • Shelves of unused office supplies • Stacks of promotional literature or pre- printed forms • Inventory of never-been-used office equipment • Excess facilities, materials and information • Excess storage space • Obsolete databases, files and folders • Emails waiting to be read • Files waiting to be worked on Inventory Waste of Inventory
  28. 28. © Operational Excellence Consulting. All rights reserved. 28 Lean Wastes in Office • Reaching, bending or unnecessary motion due to poor ergonomics and office layout • Walking to meeting room • Trips to printers and copiers • Searching for information in internet, intranet or shared folders • Searching for tools, files and supplies • Handling paperwork Motion Waste of Motion
  29. 29. © Operational Excellence Consulting. All rights reserved. 29 Lean Wastes in Office Intellect • Employees do not have the opportunity to learn new skills or utilize hidden ones • Employees are not involved in process improvement or problem solving • Time is spent correcting errors or responding to emergencies • Workers are not given the chance to advance within the company • Narrowly defined jobs and expectations • Mismatched work functions with skill sets Waste of Intellect
  30. 30. © Operational Excellence Consulting. All rights reserved. Lean Wastes in Product Development 7
  31. 31. © Operational Excellence Consulting. All rights reserved. 31 Lean Wastes in Product Development • Working with incomplete requirements • Not using standard parts and components • Extra software features • Too many prototypes • Unnecessary documentation • Cost overruns due to excessive project time charging • Overlap of strategic and non-strategic projects competing for limited resources Over-Production Waste of Over-Production
  32. 32. © Operational Excellence Consulting. All rights reserved. 32 Lean Wastes in Product Development • Product designs or processes that are too complex • Unnecessary steps in design process • Over-designed or over-engineered product • Using software that has a function beyond what is needed • Too many approvals required • Excessive number of iterations • Excessive “paperwork” Over-Processing Waste of Over-Processing
  33. 33. © Operational Excellence Consulting. All rights reserved. About Operational Excellence Consulting
  34. 34. © Operational Excellence Consulting. All rights reserved. 34 About Operational Excellence Consulting • Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. • The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions. • OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg
  35. 35. © Operational Excellence Consulting. All rights reserved. To download this presentation, please visit us at: www.oeconsulting.com.sg END OF PARTIAL PREVIEW

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