GB - 4 - Define - Elements of Waste PDF

Lean Six Sigma Green Belt
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Start and Participation Lunch and
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Exam Feedback
Course Presentation
Define Phase
Elements of Waste
Official
Elements of Waste
Understanding Six Sigma
Six Sigma Fundamentals
Selecting Projects
Elements of Waste
7 Components of Waste
5S
Wrap Up & Action Items
LSS Green Belt v12 MT - Define Phase 7 © Open Source Six Sigma, LLC
Official
Definition of Lean
“Lean Enterprise is based on the premise that anywhere work

is being done, waste is being generated.
The Lean Enterprise seeks to organize its processes to the

optimum level, through the continual focus on the
identification and elimination of waste.”
-- Barbara Wheat
Lean Six Sigma Master Black Belt
Official
Lean – History
1885 1913 1955 - 1990 1993 -

Craft Production Mass Production Toyota Production Lean Enterprise
- Machine then harden - Part inter-changeability System - "Lean" applied to all
- Fit on assembly - Moving production line - Worker as problem functions in enterprise
- Customization - Production engineering solver value stream
- Highly skilled workforce - "Workers don't like to - Worker as process - Optimization of value
- Low production rates think" owner enabled by: delivered to all
- High Cost - Unskilled labor -- Training stakeholders and
- High production rates -- Upstream quality enterprises in value chain
- Low cost -- Minimal inventory - Low cost
- Persistent quality -- Just-in-time - Improving productivity
problems - Eliminate waste - High quality product
- Inflexible models - Responsive to change - Greater value for
- Low cost stakeholders
- Improving productivity
- High quality product
Official
Lean Six Sigma
Lean Six Sigma combines the strengths of each system:
• Lean • Six Sigma

– Guiding principles based – Focus on Voice of the Customer
operating system – Data and fact based decision
– Relentless elimination of all making
waste – Variation reduction to near
– Creation of process flow and perfection levels
demand pull – Analytical and statistical rigor
– Resource optimization
– Simple and visual
Strength: Efficiency Strength: Effectiveness
An Extremely Powerful Combination!

Official
Project Requirements for Lean
• Perhaps one of the most detrimental employee performance issues in

today’s organizations is generated not by a desire to cheat one’s employer
but simply by a lack of regard to waste.
• In every work environment there are multiple opportunities for reducing
the non-value added activities that have (over time) become an ingrained
part of the standard operating procedure.
• These non-value added activities have become so ingrained in our process
they are no longer recognized for what they are, WASTE.
• waste (v.) Anything other than the minimum amount of time, material,
people, space, energy, etc. needed to add value to the product or service
you are providing.
• The Japanese word for waste is muda.
Get that stuff outta

here!
Official
Seven Components of Waste
Muda is classified into seven components:

– Overproduction
– Correction (defects)
– Inventory
– Motion
– Overprocessing
– Conveyance
– Waiting
Sometimes additional forms of muda are added:

– Under use of talent
– Lack of safety
Being Lean means eliminating waste.
Official
Overproduction
Overproduction is producing more than the next step needs or more

than the customer buys.
– It may be the worst form of waste because it contributes to all the others.
Examples are:
✓Preparing extra reports
✓Reports not acted upon or even read
✓Multiple copies in data storage
✓Over-ordering materials
✓Duplication of effort/reports
Waste of Overproduction relates to the excessive

accumulation of work-in-process (WIP) or finished
goods inventory.
Official
Correction
Correction of defects is as obvious as it sounds.
Examples are:
✓Incorrect data entry
✓Paying the wrong vendor
✓Misspelled words in
communications
✓Making bad product
✓Materials or labor discarded

during production
Eliminate errors!!
Waste of Correction includes the waste of handling and
fixing mistakes. This is common in both manufacturing
and transactional settings.
Official
Inventory
Inventory is the liability of materials that are bought, invested in and

not immediately sold or used.
Examples are:
✓Transactions not processed
✓Bigger “in box” than “out

box”
✓Over-ordering materials
consumed in-house
✓Over-ordering raw materials –

just in case
Waste of Inventory is identical to overproduction except it

refers to the waste of acquiring raw material before the
exact moment it is needed.
Official
Motion
Motion is the unnecessary movement of people and equipment.

– This includes looking for things like documents or parts as well as
movement that is straining.
Examples are:
✓Extra steps
✓Extra data entry
✓Having to look for something
Waste of Motion examines how people move to

ensure that value is added.
Official
Overprocessing
Overprocessing is tasks, activities and materials that do not add value.

– Can be caused by poor product or tool design as well as from not
understanding what the customer wants.
Examples are:
✓Sign-offs
✓Reports containing more

information than the customer
wants or needs
✓Communications, reports,
emails, contracts, etc.
containing more than the
necessary points (briefer is
better)
Waste of Overprocessing relates to over-
processing anything that may not be adding ✓Voicemails that are too long
value in the eyes of the customer.
Official
Conveyance
Conveyance is the unnecessary movement of material and goods.

– Steps in a process should be located close to each other so movement is
minimized.
Examples are:
✓Extra steps in the process
✓Distance traveled
✓Moving paper from place to

place
Waste of Conveyance is the movement of material.
Official
Waiting
Waiting is nonproductive time due to lack of material, people or

equipment.
– Can be due to slow or broken machines, material not arriving on time,
etc.
Examples are:
✓Processing once each month

instead of as the work comes in
✓Showing up on time for a

meeting that starts late
✓Delayed work due to lack of

communication from another
internal group
Waste of Waiting is the cost of an idle resource.

Official
Exercise
Exercise objective: To identify waste that occurs in your

processes.
Write an example of each type of Muda below:
– Overproduction ___________________
– Correction ___________________
– Inventory ___________________
– Motion ___________________
– Overprocessing ___________________
– Conveyance ___________________
– Waiting ___________________
Official
5S – The Basics
5S is a process designed to organize the workplace, keep it neat and

clean, maintain standardized conditions and instill the discipline
required to enable each person to achieve and maintain a world class
work environment.
• Seiri - Put things in order

• Seiton - Proper Arrangement
• Seiso – Clean
• Seiketsu – Purity
• Shitsuke - Commitment
Official
English Translation
There have been many attempts to find five English “S” words to maintain the original
intent of 5S from Japanese. Listed below are typical English words used:
1. Sort (Seiri)
2. Straighten or Systematically Arrange (Seiton)
3. Shine or Spic and Span (Seiso) Place things in such a
way they can be easily
4. Standardize (Seiketsu) reached whenever they
5. Sustain or Self-Discipline (Shitsuke) are needed.
Straighten
Shine
Sort
5S
Visual sweep of areas, eliminate
Identify necessary items and remove unnecessary dirt, dust and scrap. Make
ones, use time management. workplace shine.
Self-Discipline
Standardize
Make 5S strong in habit.
Work to standards, maintain
Make problems appear and
standards, wear safety
solve them.
equipment.
Official
Exercise
Exercise objective: To identify elements of 5S in your

workplace.
Write an example for each of the 5S’s below:
• Sort ____________________
• Straighten ____________________
• Shine ____________________
• Standardize ____________________
• Self-Discipline ____________________
Official
Summary
At this point you should be able to:
• Identify and describe the 7 Elements of Waste
• Describe 5S
• Provide examples of how Lean Principles can affect your area
Any Questions?
Official
IASSC® Lean Six Sigma Green Belt

The International Association for Six Sigma Certification (IASSC) is a Professional Association
dedicated to growing and enhancing the standards within the Lean Six Sigma Community.
An IASSC Lean Six Sigma Green Belt by PeopleCert is

an internationally recognized professional who is
well versed in the Lean Six Sigma Methodology. The
Green Belt Exam is a 3 hour, 100 question live-
proctored exam.
Learn about IASSC Lean Six Sigma Certifications and Exam options
PeopleCert
LSS Green Belt v12 MT - Define Phase © Open Source Six Sigma, LLC
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Lean Six Sigma Green Belt

PeopleCert delivers exams in over 200

2,500 Accredited Training

Online (web) proctored exams, any

Comprehensive Portfolio of 600

Software Development &

Change, Risk & Benefits Management

Business Management & Improvement

Understanding Six Sigma

Six Sigma Fundamentals

Wrap Up & Action Items

“Lean Enterprise is based on the premise that anywhere work

The Lean Enterprise seeks to organize its processes to the

1885 1913 1955 - 1990 1993 -

Lean Six Sigma combines the strengths of each system:

• Lean • Six Sigma

Strength: Efficiency Strength: Effectiveness

An Extremely Powerful Combination!

• Perhaps one of the most detrimental employee performance issues in

Get that stuff outta

Muda is classified into seven components:

Sometimes additional forms of muda are added:

Being Lean means eliminating waste.

Overproduction is producing more than the next step needs or more

✓Preparing extra reports

✓Reports not acted upon or even read

✓Multiple copies in data storage

Waste of Overproduction relates to the excessive

Correction of defects is as obvious as it sounds.

✓Incorrect data entry

✓Paying the wrong vendor

✓Making bad product

✓Materials or labor discarded

Inventory is the liability of materials that are bought, invested in and

✓Transactions not processed

✓Bigger “in box” than “out

✓Over-ordering raw materials –

Waste of Inventory is identical to overproduction except it

Motion is the unnecessary movement of people and equipment.

✓Extra data entry

✓Having to look for something

Waste of Motion examines how people move to

Overprocessing is tasks, activities and materials that do not add value.

✓Reports containing more

Conveyance is the unnecessary movement of material and goods.

✓Extra steps in the process

✓Moving paper from place to

Waste of Conveyance is the movement of material.

Waiting is nonproductive time due to lack of material, people or

✓Processing once each month

✓Showing up on time for a

✓Delayed work due to lack of

Waste of Waiting is the cost of an idle resource.

Exercise objective: To identify waste that occurs in your

5S is a process designed to organize the workplace, keep it neat and

• Seiri - Put things in order

Exercise objective: To identify elements of 5S in your

At this point you should be able to:

• Identify and describe the 7 Elements of Waste

• Provide examples of how Lean Principles can affect your area

IASSC® Lean Six Sigma Green Belt

An IASSC Lean Six Sigma Green Belt by PeopleCert is

Send us your comments at: