Eliminating The Seven Wastes

Internal, Rework, Supplier, Final Test, Inspection, Out of Control Process, Lack of skill, training and on the job support, Inaccurate design and engineering, Machine inaccuracy
7. Defects

Material Shortages, Un-level Demand, Build to stock, Economic Lot Sizes, Batching, Bottleneck processes, Unbalanced capacities, Quality problems, Long change-over times, Building Earlier than needed, Poor logistics, Poor layout, Poor machine reliability, Emphasis on keeping machines busy opposed to keeping material busy.
1. Over Production 2. Inventory

Buffers , Excess WIP, Supplier inventories for long lead time, Stock, Production Schedule not even, inaccurate forecasting, excessive downtime / setup. Poor work design, Ergonomic Design, Travel time, Tool & Material access, Inadequate Operating Procedure, Poor Housekeeping, Inadequate Training

Excessive testing, Install, Reconfiguration, Material variability/over design, Lack of operating procedures

6. Over Processing

3. Motion

5. Transporta tion

4. Waiting

Movement between buildings/sites, Premium, Freight, Distribution, Network, Plant Layout, Unnecessary material handling

Materials Shortages, Un-level Demand, Startup, Vendor Predictability, Scheduling Conflicts, Lack of flexibility in personnel or equipment, Downtime/Breakdown, Ineffective planning, Design or Quality issues, Transportation, Unnecessary material handling

L. Pennington

Predefined methodology to identify and eliminate waste.

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