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The 8
   Forms of
   WASTE

  Finding Innovation Through Teamwork

Finding Innovation Through Teamwork
What is Waste?
  • Muda (Japanese word for waste)
  • More specifically, any object or activity that
    adds NO value to the expected outcome
  • Value is in the eyes of the CUSTOMER
  • Waste absorbs both time and money,
    causing inefficiency
  • 7 forms of waste originally identified by
    Taiichi Ohno (1912-1990)


Finding Innovation Through Teamwork
Muda, Mura & Muri




Finding Innovation Through Teamwork
The Value Stream




Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Over Production
  •   Making too much
  •   Producing too early
  •   Making it “just in case”
  •   Considered the most serious of the wastes

  • Examples?
      – Making too many copies
      – Double entering/writing anything
      – Making widgets early and having them sit on the
        production floor.
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Waiting
  • When time is not used
    effectively
  • Anytime materials or
    components are not
    moving or adding value
  • Examples:
      – Waiting for people
      – Documents that sit,
        waiting for a signature
      – WIP waiting for the next
        step in a process
      – Late deliveries (supplies)
Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Transporting
  • Movement of materials within a factory
  • The number of movements = the number of
    opportunities to damage and/or deteriorate
  • Automate transportation whenever possible
  • In Japan… AGVs, material delivered to where it is
    needed (vehicle dashboards)




Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Inappropriate (Over) Processing
  • Machines and/or
    processes that are
    not capable of
    quality output
  • Using the wrong tool
    for the job
      – Cracking a nut with a
        sledge hammer
      – Cutting down trees
        with a dull axe

Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Unnecessary Inventory
  • The “enemy” of quality and productivity
  • Inventory exceeding specified quantity limit
      – Some degree of buffer inventory can be
        acceptable when supplier lead times are long
        and can not be changed.
      – Kanban should be implemented, pull
  • Negative impact on cash flow
  • Think about your office supply room…
      – Paper and toner


Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Unnecessary Motion
  • Refers the ergonomics of the workplace
  • Too much bending, turning, reaching, walking, or
    moving to do the job (ie. wrench > air ratchet > quick connect)
  • Everything you need to perform a task should be
    within arms reach and in front of you




Finding Innovation Through Teamwork
Finding Innovation Through Teamwork
Defects
  • Producing something that does not meet the
    customer’s expectation(s).
  • Internal and external failures
  • Scrap, rework, less than perfect yield,
    complaints, missing info, etc…
  • Generally, the form of waste that gets the
    most attention.
      – Why?



Finding Innovation Through Teamwork
#8
                Unused or Misused Skills / Talent
              Not taking full advantage of peoples skills, knowledge and abilities…




Finding Innovation Through Teamwork way we’ve always done it…”
                         “But that’s the
Unused or Misused Skills/Talents
  • Not going to the gemba
  • Not involving the stakeholders in problem
    solving and root cause analysis
  • Preventing people from reaching their
    potential by utilizing their abilities
  • Product of micromanaging
  • Your front-line staff are the ones charged
    with creating the value for your customers.
    Therefore, they need to be engaged.

Finding Innovation Through Teamwork
Waste Elimination Tool




Finding Innovation Through Teamwork
Finding Innovation Through Teamwork

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The Eight Wastes

  • 1. The 8 Forms of WASTE Finding Innovation Through Teamwork Finding Innovation Through Teamwork
  • 2. What is Waste? • Muda (Japanese word for waste) • More specifically, any object or activity that adds NO value to the expected outcome • Value is in the eyes of the CUSTOMER • Waste absorbs both time and money, causing inefficiency • 7 forms of waste originally identified by Taiichi Ohno (1912-1990) Finding Innovation Through Teamwork
  • 3. Muda, Mura & Muri Finding Innovation Through Teamwork
  • 4. The Value Stream Finding Innovation Through Teamwork
  • 6. Over Production • Making too much • Producing too early • Making it “just in case” • Considered the most serious of the wastes • Examples? – Making too many copies – Double entering/writing anything – Making widgets early and having them sit on the production floor. Finding Innovation Through Teamwork
  • 8. Waiting • When time is not used effectively • Anytime materials or components are not moving or adding value • Examples: – Waiting for people – Documents that sit, waiting for a signature – WIP waiting for the next step in a process – Late deliveries (supplies) Finding Innovation Through Teamwork
  • 10. Transporting • Movement of materials within a factory • The number of movements = the number of opportunities to damage and/or deteriorate • Automate transportation whenever possible • In Japan… AGVs, material delivered to where it is needed (vehicle dashboards) Finding Innovation Through Teamwork
  • 12. Inappropriate (Over) Processing • Machines and/or processes that are not capable of quality output • Using the wrong tool for the job – Cracking a nut with a sledge hammer – Cutting down trees with a dull axe Finding Innovation Through Teamwork
  • 14. Unnecessary Inventory • The “enemy” of quality and productivity • Inventory exceeding specified quantity limit – Some degree of buffer inventory can be acceptable when supplier lead times are long and can not be changed. – Kanban should be implemented, pull • Negative impact on cash flow • Think about your office supply room… – Paper and toner Finding Innovation Through Teamwork
  • 16. Unnecessary Motion • Refers the ergonomics of the workplace • Too much bending, turning, reaching, walking, or moving to do the job (ie. wrench > air ratchet > quick connect) • Everything you need to perform a task should be within arms reach and in front of you Finding Innovation Through Teamwork
  • 18. Defects • Producing something that does not meet the customer’s expectation(s). • Internal and external failures • Scrap, rework, less than perfect yield, complaints, missing info, etc… • Generally, the form of waste that gets the most attention. – Why? Finding Innovation Through Teamwork
  • 19. #8 Unused or Misused Skills / Talent Not taking full advantage of peoples skills, knowledge and abilities… Finding Innovation Through Teamwork way we’ve always done it…” “But that’s the
  • 20. Unused or Misused Skills/Talents • Not going to the gemba • Not involving the stakeholders in problem solving and root cause analysis • Preventing people from reaching their potential by utilizing their abilities • Product of micromanaging • Your front-line staff are the ones charged with creating the value for your customers. Therefore, they need to be engaged. Finding Innovation Through Teamwork
  • 21. Waste Elimination Tool Finding Innovation Through Teamwork