7 wastes

1. Add NO value - Only serve to raise costs
- Over-production
- Inventory
- Extra Processing
- Motion
- Rework (Defects)
- Waiting
- Transportation
7 Deadly Waste
Waste Exists In Every Process…Eliminate ItWaste Exists In Every Process…Eliminate It
PEOPLE
TYPES
OF
WASTE
Extra
Processing
Motion
Waiting
Rework
Over-
ProductionTransportation
Inventory
QUALITY
QUANTITY

2. Waste 1  Over-Production
Builds inventory
not needed
Produce or order only what, when and in the quantity needed
Creating reports no
one reads
Hides other process
problems (bad quality,
poor delivery)
Takes up floor /
disk space
Effects
Causes
Working on the
wrong priority work
Producing more than the
customer or next process needs

3. Waste 2  Inventory
Difficulty in
finding material
Useless Emails in
the Inbox
Takes valuable
space
Need extra
resources to
manage
Effects
Causes
Populating hard disk
with data
Lots of inventory on shelves,
racks and floors
Obsolescence
Losses due to
damage
Efficient use of inventory… Not Just-in-Case inventory
Inventory Hides ProblemsInventory Hides Problems

4. Inventory Hides ProblemsInventory Hides Problems
Less Inventory Exposes ProblemsLess Inventory Exposes Problems

5. Waste 3  Extra Processing
Opportunity for
more defects
Creates Delay in
Delivering
Effects
Causes
Incomplete
Information
supplied
Multiple ways of
doing the same
task
Eliminate Excess work
Checking /
Rechecking (Non-
Standardization)

6. Waste 4  Unnecessary Motion
Wasted cycle time
Extra Clicks or
key strokes
Adds cost
Effects
Causes
Unnecessasry
Movement of People
Before After
Handling
Paperwork

7. Waste 5  Rework (Defects)
Adds cost
Create Delay in
Delivery
Consumes resources
in rework
Effects
Causes
Lack of Clarity
on Requirement
Unnecessary
Changes in
Decision
Incomplete or
incorrect inputs
Reduce Defects
Discourage customer
satisfaction
Escalated impact of initial defect if passed on to next process

8. Waste 6  Waiting
Increases work
in progress
Idle time due to
lack of “Standard”
operations
Adds to cycle
timeCauses bottlenecks
Effects
Causes
Waiting for people,
information, etc
Slows response to
customer
When Inventory Waits, Customer Waits
Lack of
Coordination

9. Waste 7  Transportation
Movement of things
Adds to cycle time
Consumes valuable resources
Effects
Causes
Excessive Emails Taking files to
another person
Adds cost

10. Time Spent
Searching
Waiting
Reworking
Time Spent
Correcting
Waiting
Re-Checking
Waste = 80 % Value = 20 %

11. Value vs. Waste