7 DEADLY WASTES

1. The Seven Deadly Wastes
Course Objectives
 Learn what the Seven Deadly Wastes
are and how they affect our business.
 Identify the Waste in our business and
develop an action plan to eliminate it.
 Develop an action plan to teach others
what the Seven Deadly Wastes are and
how to eliminate them.

2. First – The History Lesson
 Have you heard of Mass Production?
This method of production was brought
to the forefront with Henry Ford’s
invention of the automobile.
Lean
Manufacturing
Mass Production
Skilled
Craftsmanship
1900’s 1930’s 1960’s TODAY

3. Dr. Deming Enters the Scene
Following WWII, the lean manufacturing
approach was developed by American
Dr. Edward Deming, to assist the
Japanese economy in rebuilding from
the impacts of war. The scarcity of raw
materials provided the basic premise for
lean manufacturing, i.e., use what is
on hand in the most efficient manner.

4. Great Cars from Japan?
How were the first cars from Japan
viewed?
How are cars from Japan viewed
today?
Welcome the age of Lean
Manufacturing.

5. The Toyota Production System
 In the early 1960’s TPS was pioneered
by Taiichi Ohno to reflect the
philosophies of waste elimination and
time management
 Highly skilled “work cell” jobs
 Emphasis on quality and efficiency

6. TPS Top Three
1. The team must embrace a philosophy
of having zero tolerance for waste
2. Activity on a daily basis is focused on
creating a stable production
environment.
3. Systems are set up to create
customer “Pull” or Just-in-Time
Delivery

7. Zero Tolerance For Waste
 All unnecessary waste can be
eliminated
 Stated simply, the goal is perfection

8. Stable Production Environment
 The highest quality product can only be
achieved in a stable environment.
Problems are instabilities that must be
surfaced quickly and solved
permanently
 Standardization, consistency and
predictability and repeatability are the
goals. Improve from there!

9. Customer Pull/JIT Delivery
 A product should only be built to meet
customers demands. Build only what
the customer wants, deliver it when it is
expected and with perfect quality
 This approach results in the best use of
the company’s resources, which leads to
greater profitability

10. Let’s get into the Waste

11. What are you willing to pay
for?
 Dough, Sauce, Toppings, Toppings dropped
on the floor, Labor cost for delivery driver,
Labor cost for delivery driver to stop at
girlfriend’s house on the way?
 What are our customer’s willing to pay for?
VALUE ADDED ACTIVITY

12. Value Added Activity
Value is added to a product when it changes
the fundamental nature of the product.
Examples:
 Stamping a bracket out of a coil of steel
All other activities are non-value added or
waste

13. And here they are . . .
1. Overproduction
2. Inventory
3. Transportation
4. Waiting
5. Motion
6. Over Processing
7. Correction or Rework
W A S T E

14. Overproduction
Overproduction is making more of
something than the customer requested
Examples:
 Running a machine for 16 hours
when only 10 are required
 Making 2 day’s worth of product
when only 1 day’s worth is required

15. Inventory
Inventory waste occurs when there is
more product on hand than the
customer requested.
Examples:
 More raw material than needed for
smooth production
 More work-in-process

16. Transportation
Transportation waste is moving the
product more than is necessary
Examples:
 Having three storage locations for the
same material
 Moving raw materials to an offsite
warehouse

17. Waiting
Anytime value cannot be added because
of a delay is defined as the waste of
waiting
Examples:
 Waiting for material
 Waiting for a machine to be fixed
 Unbalanced assembly sequence

18. Motion
The waste of motion refers to any extra
movement of the operator when they are
performing the work sequence (excessive or
repetitive motion also increases ergonomic
issues)
Examples:
 Walking 10 feet to retrieve a part or tool
 Twisting around to grab a part in the back
of the workstation

19. Overprocessing
Over processing is doing more to the
product than the customer requested
Examples:
 Plating a product for four hours when
only two are required
 Testing a product three times when
the specification calls for one test

20. Correction/Rework
Anything that is not “done right the first time”
and requires rework inspection or touchup
(Also includes scrap and appearance issues )
Examples:
 Re-torquing a bolt
 Sorting incoming materials
 Checking a key dimension
 Trimming thread or flash from a
component

21. Waste in my cell!!
Waiting
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Inventory
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Motion
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Transportation
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Overproduction
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Over Processing
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Correction
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22. Action Plan for Eliminating
Waste and Teaching Others
1.
2.
3.
4.
5. Discuss this with my coach.