Muri-Mura-Muda

MURI – STRAIN
MURA – INCONSISTENCY / IMBALANCE
MUDA – WASTE
3 M’s
Ignite2Shine
Quality Steps info | www.ignite2shine.com | Con: 91-8510001499

Elimination of MUDA
What is MUDA
Operation = Work + MUDA
Work = Increases value of production
MUDA = Increases cost of production
Kaizen
(Improvement)
Total amount of labour No Change
Lobour Density Effectiveness =
Work
Work + MUDA
To 100%
= Work MUDA
MUDA
Workin
g
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Reduce Cost
Material
Cost
Energy
Cost
Processing
Cost
Others
Cost Price
Processing
Conveyance
Inspection
Stagnation
Useful Job
from customer
point of view
MUDA
Worthless Job does
not increase value to
the process
Decided by manufacturing method
Actual movement for Reducing Cost
Remove MUDA
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 MUDA of Overproduction
 MUDA of Stock
 MUDA of Conveyance (Transport)
 MUDA of Waiting
 MUDA of Operation Itself
 MUDA of Movement of Worker
 MUDA of Production of Inferior goods
Types of MUDA
MUDA
Monster
Profit
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Over Production is the Worst MUDA
 Increase Raw Material Purchasing
( MUDA of Stock)
 Increase Workers
 Add Machines
Loose
Money
Neces-
ary
Q’ TY
Over
Production
Meaningless Increase of Efficiency
10 Workers : 100 Products
10 workers : 120 Products
Necessary Q’ TY : 100
Over Production
Store House Conveying
Equipment Bin
Additional ware House
Loose
Money  Conveyance
 Interest Rate
Moving Material which is
not Required
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Sample of MUDA
MUDA of Overproduction
Before Installing Pipe on Vehicle
Make a lot of Pipe on
Preparation
Table
Only one is necessary
on a car
Within one cycle
to make only necessary
Q’TY
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 Indicator measures how frequently the stock of raw
material, work-in-process and finished goods are turned
over in relation to the sales revenue of a product.
 Inventory levels are key indicators of the “leanness” of the
process and are directly related to the simplicity of
production flows.
(Material cost of sales in particular month)
 ITR = ---------------------------- ------------------------- X 12
(Inventory RM+WIP+FG as on date)
 This indicator should increase over time
Inventory Turn Ratio—ITR
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Inventory Turn Ratio—ITR
 Company should define its method of calculation of
material cost, inventory compilation.
 Company should take a stock of the inventory of the
RM, WIP, FG on the last day of a month and
calculate ratio
 Include all products owned even if they are not
physically located on-site (e.g. material at the
subcontractor for job work, material at warehouse,
consignment stock held at Customers)
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 Will add cost of :-
– Tools
– Inventory
– Poor Life
– Scrap due to method change (Obsolete)
– Storage and upkeep
– Searching
MUDA of Stock
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MUDA of Transportation (Case 1)
This worker is changing
parts to new pallet.Loading
Transfer
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MUDA of Transportation
Install
Carry
Carry
To Temporary
Store
From
Ware
House
To Plant
Next
Next
to the
Machine
To the Opera
Aren’t you doing this kind
of useless transport?
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MUDA of Movement
Worker go to take a tool repeatedly:- To the rack every time
Shortage of a
Tool
bit/Socket
Small
bag
For
small
part and
tool bits
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Adoption of part box
MUDA of Movement of Worker
Worker go to take parts
repeatedly:- (4 time)
Part Box
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Reduction of walking distance (Case 1)
MUDA of Movement
Working order is
change
1 2 3 4 5 61 4 6 2 5 3
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Improvements in WORK METHODS
 Is there a different way of doing it ?
 Can you oversee a greater no. of machines ?
 Can the time spent for waiting be used for some other purpose?
 Can a single motion replace several motions ?
 Can a troublesome set-up be eliminated ?
 Can a machine do a manual task?
 Can a process be shortened or eliminated?
 Can a rhythmical motion be used?
 Can a more comport posture be used?
 Are both hands being used?
 Can your foot be used ?
 How about changing the position of handles, switches and levers?
Ignite2Shine

MUDA of Waiting
While Filling
water in A C
Do other job
Bad case
Waiting until a can is filled
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MUDA of Waiting (Case 1)
While operating, worker is standing
“Waiting MUDA”
Radiator Support StandardWorking
Time
WorkingName
MUDA
Auto
Working
SEC
1. WeldingNut 2
2. ReinforceSpot 2
3. Set Insulator 6
Waiting
MUDA
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MUDA of Waiting (Case 2)
Operator has to walk long distance
Within arms reach (2’S’)
Due to rearranging parts
save moving distance
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MUDA of Waiting
 Examples : -Waiting For
• Tools
• Oil
• Material
• Set up Approval
• Packing
• Machine repair
• Cycle to complete
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MUDA of Operation
Installation of bolt and screw (Two types of head)
Worker uses 2 Kinds of Air Tool
For Screw
For Bolt
Improvement of Air Tool
Combining / modifying to use both
without changing the impact wrench
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MUDA of Waiting (contd.)
 Will add cost of:-
• Less productivity
• Under utilization of equipment’s
• Under utilization of people
• Compensation of incurred loss
• Overall less out-put of line due to stoppage of one
equipment
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MUDA of Production of Inferior Goods
Due to incomplete of installation of tool and Jig
MUDA (Inferior goods) of manufacturing
1. Hard to Work
2. Inferior to Specification
3. Worn Socket
4. Incomplete Tool
5. Take more time to do
Do operation over again
Use Jig
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MUDA of Production of Inferior Goods
– Rework
– Scrap
– Disposal of scrap
– Time of Rework
– Manhours for Rework
– Preserving defective Material
– Segregation
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MUDA of Production of Inferior Goods (contd.)
– Defective parts going undetected to next process
– Trial Scrap
– Loosing Customers
– Decrease in Yield
– Warranty Claims
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MUDA of Operation itself
– Excess power consumption
– Rework due to Bad Quality
– Scrap
– Excess cycle time due to not following SOP
– Extra Movement of operator
– Costlier Tooling
– Running the machine with No / Less load
– Not using the tool for 100% of it’s life
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MUDA of Operation itself (contd.)
– Not producing as per designed rate
– Delayed Set-Up
– Breakage of tools
– Man days lost due to ACCIDENTS
– Frequent Adjustment for desired Quality
– Frequent Break-downs
– Idleness due to Poor Rhythm of other operations
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MUDA of Operation itself (contd.)
– Frequent coolant change
– Using additional lighting
– Poor life of Replacement parts (Bearing)
– Doing separate operation instead of combining operations
– Reducing Speed / Feed because of Input Quality / Tooling
– 100% Inspection
Ignite2Shine

MURA = Unevenness
– Variation in Quality
– Unbalanced Capacities of Various Machines
– People are too busy in one area and too idle in other area
– Mixing up of Experienced and inexperienced workers wrongly
– Unevenness in the provision of Training and Instructions
– Irregularity in Tooling Quality
– Using Equipment unreasonably or wastefully
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MURI = Strain
– Trying to use Low-Precision Equipment for High-Precision
Processing
– Running machines beyond it’s designed capacities
– People getting over-tired through working in strained postures
– Doing a work manually that ought to be done by machines
– Strain due to poor design
– Increased workload due to non-availability of people to cope it
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Muri-Mura-Muda

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