Waste

Elimination of Waste
 Contents of an Operation
Value Added Work
The part of the job the customer wants to pay for

Non Value Added or Hidden Waste

Work that does not add value but is necessary under the
current operating conditions

Obvious Waste
Work that does not add value and is not necessary
WASTE
What is Value Added Work?
Work that increases the value of a part.
i.e. that which changes the fit, form or function

e.g. Press forge

bend roll
cut point
Drill heat treat
Form plate glue
Weld assemble
Paint

polish ….
Maximise these activities
What is Hidden Waste?
Work that does not add value but is necessary
under the current operating conditions.
➢ tool changeover
➢ inspection
➢ parts handling
➢ unavoidable transportation parts
➢ unwrapping of purchased parts

Minimise these activities

What is Obvious Waste?
Work that does not add value
and is not necessary.
1. Overproduction
2. Waiting
3. Transportation
4. Process
5. Inventory
6. Operator Movements
7. Defects

Eliminate these activities

7 Wastes - Overproduction
1. Making more than the customer needs
➢ Making in large batches
➢ Overrunning an unstable process
➢ To produce more than is required*
➢ To produce before required*
* (by internal or external customer)

Overproduction
 7 Wastes of - Waiting
2. Man or Machine Waiting
➢ Waiting for material
➢ Waiting for maintenance waiting-time

➢ Waiting for Tool change

➢ Waiting for Quality check
➢ Waiting for next station
➢ Waiting for quality checks
➢ Nonvalue added work in cycle
➢ Operator inactivity during cycle
➢ Machine inactivity during cycle
7 Wastes - Transportation
3. Material/Parts Movement
➢ Unnecessary moving or handling of parts.
➢ Handling equipment moving with no parts.
➢ Raw material batch sizes not matching production batch size.
➢ Material stored a long way from point of use.
7 Wastes - Process
4. Inefficient Process
➢ Wrong choice of equipment
➢ Bad definition of customer's needs
➢ Useless operations
➢ Excessive movement in process cycle
➢ Too frequent inspections
➢ Excessive set-up or downtime
➢ Slow complicated processes
➢ Useless refinement
➢ Bottlenecks
➢ Unbalanced process
7 Wastes - Inventory
5. Large Stocks
➢ Stock pile of finished goods
➢ High WIP
➢ High raw materials
➢ Excessive racking and warehouse space
➢ Excessive handling equipment

Just In Time Just In Case

The 7 Wastes 10
Types of Waste - Inventory
Inventory conceals problems, makes control difficult and
obscures the opportunity for improvement.
➢ Delays action in dealing with faults
and defects Eliminate rocks
➢ Reduces need to face up to fast tool = solve problems
changeovers = eliminate waste
➢ Conceals imbalance in facility
capability
➢ Goods can become damaged or
obsolete
➢ Creates unnecessary searching and Machine
breakdown
Supplier
movement of materials Long
travelling
delivery

➢ Conceals excess personnel parts

➢ Takes up space

Inventory Costs £££ !

The 7 Wastes

11
7 Wastes - Operator Movements
6. Useless motion
➢ Looking for tools, materials etc
➢ Double Handling
➢ Turning
➢ Bending
➢ Stretching
➢ Walking
➢ etc…
 7 Wastes - Defects
7. Less than Perfect Parts
➢ Trimming
➢ Scrap
Defects
➢ ➢ Rework
Rejects
➢ Recalls
➢ Delay due to defects
➢ Transportation due to defects
➢ Re-inspection and sorting
➢ Rework area inside production process
➢ Overtime to meet demand due to poor quality
What is Obvious Waste?
Work that does not add value
and is not necessary.
1. Overproduction
2. Waiting
3. Transportation
4. Process
5. Inventory
6. Operator Movements
7. Defects

Eliminate these activities