Professional Documents
Culture Documents
Waste
Introduction
Elimination of Waste
Elimination of 7 Types of Waste
Marek Piatkowski – January 2017
http://twi-network.com
Value Added Work - operations which increase a value of a product from the
Customer’s point of view
Non-Value Added Work – Incidental Work. Work that does not have any particular
value, but it has a cost.
The higher the value-added operation in your completed work, the higher the level
of production efficiency will be.
When walking and looking at different operations you will find that the actual
“work” which adds value to the material is surprisingly small, while waste or an
activity which doesn’t increase value of a product is remarkably large.
Value
Added Work
Non-Value
Added Work
WASTE
(Muda)
Waste (Muda) - is NOT work. Waste are activities, motions, behaviors or actions
that are not part of the actual work (non essential activities).
Waste refers to such things as: waiting, repairing, sorting, inspecting, verifying,
checking, counting and rearranging materials unnecessarily, or handling parts that
are not needed right away
Two major contributors to Waste:
Unevenness - fluctuating schedules, planning and production quantities
Overload - machine or employee pushed beyond natural limits of their capacity
Thinking win, Win, WIN
Marek.Piatkowski@Rogers.com 8
Elimination of
Waste
Introduction Toyota’s Chairman
Fujio Cho
Waste - Muda
Value Added Work Waste
- welding bracket - inspecting
- cooking - rearranging parts
- assembling cover - repairing
- painting frame … - waiting …
Unnecessary Transportation
Unnecessary Processing
Both forms of waste are undesirable, however, particular attention must be paid to the latter since
parts should not be produced earlier than necessary.
One of the basic production principle of Lean is to produce to customer demand, that is producing
only what is necessary, when it is needed, and in just the amount needed.
Waste of Overproduction occurs when an operator uses a machine or a process simply because it is
big, expensive, and capable of making lots of parts.
Ignoring the required production volume and producing too much is waste. Keep this in mind -
producing things that do not sell or that we do not need is waste.
Overproduction creates more work and expenses which are unnecessary: when stocks of finished
parts pile up, extra pallets, trays and containers are required to contain them.
Furthermore, extra expenses grow out of transport between processes and between the
production lines and warehouse
This type of waste has no connection with advancing the line or improving the
quality or the value of the product.
There are many instances of parts being processed excessively. For example, parts
which only require rough surfaces (non critical surfaces not apparent to the
customer) may be excessively finished, machining operations that cut threading
holes deeper than required, or machining unnecessary features on a part.
Waste of correction arises from having to inspect, correct or repair defects. All
time, material, labor and energy involved in repairs is waste. All repairs raise costs.
Even if a defective part can be repaired, its quality is often inevitably impaired. It
can also lead to quality problems further down the line and cause additional waste
of labor and energy which increases costs.
Lean Transformation does this by identifying Waste (Muda) in work and then taking
steps to eliminate it.
Traditional
Cost VA NVA
Reduction
Lean
Focus VA NVA
Elimination of Waste
First step towards efficiency improvement
Difficult to recognize waste
Need to make waste obvious to everyone
Waste must appear distinctly and clearly
Must re-examine the way we think about waste
Understanding the causes of waste and eliminating them from the work sites is
important to the production system. There are two other contributors to waste:
Unevenness
Overburden
If we carefully analyze each work process, the equipment and materials being used,
we soon can identify waste and find ways to eliminate it.
Working Longer
Working overtime, working weekends or holidays
This method of increasing production may be effective if done infrequently for relatively short
periods of time
It is a poor solution in the long run
Marek.Piatkowski@rogers.com
http://twi-network.com
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