The document discusses different types of waste or "muda" in lean manufacturing. It defines the seven main types of muda as over-production, processing, transport, waiting time, inventory, motion, and defects. It also explains the Japanese terms "mura" as unevenness or variability that can lead to muda, and "muri" as overburden or unreasonableness. The goal of lean is to identify, measure, and eliminate all forms of waste from production processes.

1. Preventing and eliminating
muda
Pre. By jaleto S.

2. » Identify Safety equipment and tools
» Tools and techniques are used to draw
and analyze current situation of the
work place.
» Wastes/MUDA are identified and
measured based on relevant
procedures.
» Necessary attitude and the ten basic
principles for improvement are
adopted to eliminate waste/MUDA.
» wastes/MUDA are prevented by using
visual and auditory control methods
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The trainee you will be able to:

3. “
What is Waste?
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4. Waste is 4
The elimination of waste is the primary goal of any lean system. In effect, lean
declares war on waste – any waste. Waste or muda is anything that does not have
value or does not add value.
Waste is something the customer will not pay for.
When the great Italian sculptor Michelangelo was asked what he was sculpting,
he responded he was not sculpting but releasing the figure (value) inside by
removing the unnecessary rocks (wastes).

5. The steps to effective waste elimination are
1. Make waste visible.
2. Be conscious of the waste.
3. Be accountable for the waste.
4. Measure the waste.
5. Eliminate or reduce the waste
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6. What are the seven types of wastes or “muda”?
» A lean system declares war on wastes or “muda”. These wastes are classified into 7
types:
» Over-production waste
» Processing waste
» Transport waste
» Waiting-time waste
» Inventory waste
» Motion waste
» Defects
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7. Over-production waste
» Definition
» producing more than what is needed
» producing faster than what is needed
» Causes
» volume incentives (sales, pay, purchasing)
» high capacity equipment
» line imbalance; poor scheduling/shifting
» poor production planning
» cost accounting practices that encourage build up of inventory
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8. Producing more than your customer is requesting or before they request
it 8

9. Processing waste
» non-value added man processing
» non-value added machine processing
» Causes
» unclear customer specifications
» frequent engineering changes
» excessive quality (refinements)
» inadequate value analysis/value engineering
» unclear work instructions
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10. Unnecessary manual work that does not contribute
value to the product 10

11. Transport waste
» Definition
» unnecessary material movement
» unnecessary tools or equipment movement
» Causes
» poor route planning
» distant suppliers
» complex material flows
» poor layout
» disorganized workplace
» line imbalance
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12. Cont…
» Unnecessary conveyance of products, from one location to
another, or handoff from one employee to another
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13. Waiting time waste
» Definition
» man idle or waiting time
» machine idle or waiting time
» Causes
» unsynchronized processes; line imbalance
» inflexible work force
» over-staffing
» unscheduled machine downtime
» long set-up
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14. Waiting done by customers or by employees
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15. Inventory Waste
» Definition
» excessive process (WIP) inventories
» excessive raw material inventories and supplies
» Causes
» over-production
» imbalanced line
» big batch sizes
» long lead times
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16. More materials or information than is required
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17. Motion Waste
» Definition
» unnecessary movement and motions of worker
» Causes
» poor lay-out and housekeeping
» disorganized work place and storage locations
» unclear, non-standardized work instructions
» unclear process and materials flow
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18. Unnecessary physical or mental motion often associated with searching
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19. Defects
» Definition
» processing due to the production of defects
» processing due to rework or repair of defects
» materials used due to defect and rework
» Causes
» unclear customer specifications and incapable processes
» lack of process control
» unskilled personnel
» departmental rather than total quality
» incapable suppliers
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20. 20

21. What are 3M
» 3M
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muda
Muri
mura

22. Muda
 Muda means wastefulness, uselessness and futility,
which is contradicting value-addition. Muda refers to
processes or activities that don’t add value.
 These types of waste do not help your business or
workers in any way. They increase costs and make
tasks take much longer than they should.
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23. What are TIMWOOD?
» Transport i.e., excess movement of product
» Inventory i.e., stocks of goods and raw materials
» Motion i.e., excess movement of machine or people
» Waiting
» Overproduction
» Over-processing, and
» Defects
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24. Mura
» Mura means unevenness, non-uniformity, irregularity, and variability.
This is the reason for the existence of any of the seven wastes. In other
words, Mura drives and leads to Muda. Variability can take multiple
aspects; different bottle filling levels in a filling line, varying cutting
length, or inconsistent color tones in successive batches, etc.
» The physical characteristics of a raw material may vary over time or
according to different batches supplied; quantity, weight, length, texture,
hardness, elasticity, etc. The settings of a machine may vary over time,
human practices and actions may vary from one person to another and
over one day.
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25. Muri
» Muri means overburden, beyond one’s power,
excessiveness, impossible or unreasonableness. In other
words, Muri means unreasonableness, like the use of
oversized or excessive means relative to the need or the
desired result. Muri is also about the physical overload, the
hardship, exposure to mental stress, which lead to wasting
energy, health and ultimately human capital.
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26. THANKS FOR ATTENTION!