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Waste Walk / Audit

“Structured process to eliminate waste
   with the appropriate Lean Tools”

       Anand Subramaniam
“Don't waste good iron for nails or good men
                for soldiers.”

                               - Chinese Proverb




                                               2
Transport
          Waste                       Causes             Counter Measures
• Moving parts in and out    •   Safety              •    Kanban
  of storage                 •   Storage             •    Flow lines
• Moving material from one   •   Push production     •    Pull system
  workstation to another     •   Over production     •    Value Stream
• Capital Expenditure        •   Functional layout   •    Supply chain
                             •   Increases damage         management
                             •   Batch production
                             •   Multiple staging
                                 points




                                                                         3
Excess Inventory
            Waste                        Causes                Counter Measures
•   Raw materials                 • Lack of flow           •    Build to order
•   Finished goods                • Long set-ups           •    Internal kanban
•   Work in process               • Long lead-times        •    External kanban
•   Consumable supplies           • Over production        •    Set-up reduction
•   Purchased components          • Paperwork in process   •    One-piece flow
•   High levels of safety stock   • Lack of ordering            lines Supplier
                                    procedure                   development
                                  • Long queues in
                                    service operations
                                  • Large deposits of
                                    material at each
                                    operation

                                                                                   4
Excess Motion
            Waste                       Causes         Counter Measures
•   Non ergonomic moves          • Unsafe             • 5S
•   Reaching for tools           • Cycle time         • One-piece flow
•   Lifting boxes of parts       • Inefficiency       • Workstation
•   Sorting through materials    • Missing items        design
•   Searching for BOMS,          • Unsafe work area   • POUS
    parts, tools, prints, work   • Disorganised       • Water Spider (one
    instructions, etc.             workplace            who performs a
                                 • Poor workstation     wide range of tasks
                                   design               – stocks the line)
                                                      • 3P (Production
                                                        Preparation &
                                                        Process)
                                                                          5
Waiting
            Waste                     Causes             Counter Measures
•   Waiting for parts         • Lack of priority     •    TPM
•   Waiting for prints        • Work imbalance       •    Jidoka
•   Waiting for machines      • Push production      •    Office Kaizen
•   Waiting for inspection    • Order entry delays   •    Downstream pull
•   Waiting for information   • Centralised          •    In-process gauging
•   Waiting for machine         inspection           •    Takt time
    repair                    • Lack of                   production
                                communication




                                                                            6
Overproduction
           Waste                       Causes            Counter Measures
• Producing more to avoid      •   Forecasting          • TPM
  set-ups                      •   Long set-ups         • Set-up reduction
• Producing product to         •   Poor Communication   • Pull system
  stock based on sales         •   “Just in case” for     scheduling
  forecasts                        breakdowns           • Heijunka -level
• Batch process resulting in                              loading
  extra output
• Working on the wrong
  parts at the wrong time
• Making more parts than
  your customer needs

                                                                             7
Overprocessing
             Waste                          Causes                  Counter Measures
•   Inspection                    •   Push system               •   3P
•   Paperwork                     •   VOC not understood        •   5S
•   Over-tight tolerances         •   Unnecessary approvals     •   Flow lines
•   Multiple cleaning of parts    •   Redundant processes       •   Lean Design
•   Awkward tool or part design   •   Delays between            •   Office Kaizen
•   Consumes valuable                 processing                •   One-piece pull
    resources                     •   Opportunity for more
•   Designs “thrown over the          defects
    wall”                         •   Processing beyond
                                      specification limits or
                                      customer requirements
                                  •    Unnecessary record
                                      retention

                                                                                       8
Defects
           Waste                         Causes              Counter Measures
•   Scrap                       •   Process failure      •   3P
•   Defects                     •   Mis-loaded part      •   Jidoka
•   Rework                      •   Batch process        •   Six Sigma
•   Variation                   •   Inspect-in quality   •   Poka Yoke
•   Correction                  •   Incapable machines   •   Built-in quality
•   Field failure                                        •   One Piece Flow
•   Missing parts
•   Wrong parts from supplier




                                                                                9
Under Utilised Talent
            Waste                  Causes               Counter Measures
•   Poor quality            • Mistrust              •   Kaizen
•   High turn over          • Lack of goals         •   Job rotation
•   High Absenteeism        • Poor training         •   Cross training
•   Poor job satisfaction   • Poor communication    •   Empowerment
                            • Lack of               •   Problem Solving
                              empowerment           •    Idea
                            • No control over           implementation
                              situations
                            • Lack of feedback on
                              ideas



                                                                          10
Waste Audit
                                                           How will we know we
                        Possible Cause   Proposed Action
                                                            were successful?

Transportation

Excess Inventory

Excess Motion

Waiting

Overproduction

Overprocessing

Defects

Under Utilised Talent


                                                                           11
Waste Measures
 By numbers:
   Loads
   Contents


 By observation:
   Survey
   Photos (before and after)


 By impact:
   Problem solved (through Improvement Idea)
                                                12
Waste Removal – Improvement Ideas




                                    13
Follow-up Activities




                       14
“Give a man a beer, waste an hour. Teach a
     man to brew, and waste a lifetime!”

                                   - Bill Owen




                                            15
Good Luck
http://www.linkedin.com/in/anandsubramaniam




                                              16

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Waste Walk ~ Audit

  • 1. Waste Walk / Audit “Structured process to eliminate waste with the appropriate Lean Tools” Anand Subramaniam
  • 2. “Don't waste good iron for nails or good men for soldiers.” - Chinese Proverb 2
  • 3. Transport Waste Causes Counter Measures • Moving parts in and out • Safety • Kanban of storage • Storage • Flow lines • Moving material from one • Push production • Pull system workstation to another • Over production • Value Stream • Capital Expenditure • Functional layout • Supply chain • Increases damage management • Batch production • Multiple staging points 3
  • 4. Excess Inventory Waste Causes Counter Measures • Raw materials • Lack of flow • Build to order • Finished goods • Long set-ups • Internal kanban • Work in process • Long lead-times • External kanban • Consumable supplies • Over production • Set-up reduction • Purchased components • Paperwork in process • One-piece flow • High levels of safety stock • Lack of ordering lines Supplier procedure development • Long queues in service operations • Large deposits of material at each operation 4
  • 5. Excess Motion Waste Causes Counter Measures • Non ergonomic moves • Unsafe • 5S • Reaching for tools • Cycle time • One-piece flow • Lifting boxes of parts • Inefficiency • Workstation • Sorting through materials • Missing items design • Searching for BOMS, • Unsafe work area • POUS parts, tools, prints, work • Disorganised • Water Spider (one instructions, etc. workplace who performs a • Poor workstation wide range of tasks design – stocks the line) • 3P (Production Preparation & Process) 5
  • 6. Waiting Waste Causes Counter Measures • Waiting for parts • Lack of priority • TPM • Waiting for prints • Work imbalance • Jidoka • Waiting for machines • Push production • Office Kaizen • Waiting for inspection • Order entry delays • Downstream pull • Waiting for information • Centralised • In-process gauging • Waiting for machine inspection • Takt time repair • Lack of production communication 6
  • 7. Overproduction Waste Causes Counter Measures • Producing more to avoid • Forecasting • TPM set-ups • Long set-ups • Set-up reduction • Producing product to • Poor Communication • Pull system stock based on sales • “Just in case” for scheduling forecasts breakdowns • Heijunka -level • Batch process resulting in loading extra output • Working on the wrong parts at the wrong time • Making more parts than your customer needs 7
  • 8. Overprocessing Waste Causes Counter Measures • Inspection • Push system • 3P • Paperwork • VOC not understood • 5S • Over-tight tolerances • Unnecessary approvals • Flow lines • Multiple cleaning of parts • Redundant processes • Lean Design • Awkward tool or part design • Delays between • Office Kaizen • Consumes valuable processing • One-piece pull resources • Opportunity for more • Designs “thrown over the defects wall” • Processing beyond specification limits or customer requirements • Unnecessary record retention 8
  • 9. Defects Waste Causes Counter Measures • Scrap • Process failure • 3P • Defects • Mis-loaded part • Jidoka • Rework • Batch process • Six Sigma • Variation • Inspect-in quality • Poka Yoke • Correction • Incapable machines • Built-in quality • Field failure • One Piece Flow • Missing parts • Wrong parts from supplier 9
  • 10. Under Utilised Talent Waste Causes Counter Measures • Poor quality • Mistrust • Kaizen • High turn over • Lack of goals • Job rotation • High Absenteeism • Poor training • Cross training • Poor job satisfaction • Poor communication • Empowerment • Lack of • Problem Solving empowerment • Idea • No control over implementation situations • Lack of feedback on ideas 10
  • 11. Waste Audit How will we know we Possible Cause Proposed Action were successful? Transportation Excess Inventory Excess Motion Waiting Overproduction Overprocessing Defects Under Utilised Talent 11
  • 12. Waste Measures  By numbers:  Loads  Contents  By observation:  Survey  Photos (before and after)  By impact:  Problem solved (through Improvement Idea) 12
  • 13. Waste Removal – Improvement Ideas 13
  • 15. “Give a man a beer, waste an hour. Teach a man to brew, and waste a lifetime!” - Bill Owen 15