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4/10/2016 1
 About ME
Mohammed K. Barakat

• Industrial Engineer, The University of Jordan

• Business Excellence Manager-FINE Hygienic Paper Company
• Professional Engineer in Industrial Engineering (PE), (JCPQA-JEA)
mohammedbarakat
• Project Management Professional (PMP), (PMI)
• Risk Management Professional (PMI-RMP), (PMI)
MohdBarakat
• Certified Six Sigma Black Belt (CSSBB), (ASQ)
• Certified Six Sigma Green Belt (CSSGB), (ASQ) MohdKBarakat
• Microsoft Certified Technology Specialist (MCTS), (Microsoft)
• Microsoft Certified Trainer (MCT), (Microsoft)

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What is Waste?

Waste or muda is anything that

does not add value to the product
or service.

Waste is something the

customer will not pay for.

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Waste Elimination
Study the
process

Sustain the Recognize the

improvement wastes

Measure the
Eliminate or reduce
waste
the root cause

Identify the root

cause

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 Cause & Effect
The 7 M’s The 8 Wastes

Defect
Man/Woman
Overproduction
Method
Machine Waiting
Neglected Resources
Material
Transportation
Measurement
Mother Nature Inventory
Motion
Mindset
Extra Processing
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 The 7 M’s
Men/Women
Manual and mental skills used by a person to execute
an assignment
 Example: lack of training

Methods
The sequences and steps necessary to convert
material or information into a product or service.
 Poorly designed procedures or lack of standard work
with inconsistent application create waste.

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 The 7 M’s
Machines
Mechanical, electrical or electronically operated
devices used to perform a task
 using the wrong machine for the wrong task.
 Poorly designed tools

Material
Physical matter or information converted or acted on
to create another form with added value.

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 The 7 M’s
Measurements
An action using a physical device to record a characteristic
and compare it to a standard or expected outcome.
 Used only if the waste cause is the instrument itself. If the person taking the
measurement causes the error, categorize it as either Men/Women or Methods.

Mother Nature
The environment and immediate surroundings of the task or process

 weather, humidity, moisture, temperature, wind, noise, dust,

odors, lighting, ground, and vibration

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 The 7 M’s
Mindset
The fixed mental attitude about a situation, event or belief.

 May be derived from culture, value system, experience, or

management directives.
 Characterized by inflexibility and does not allow
for change or new ideas.

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 DOWNTIME
Defects
A product or information that does not meet customer expectations.
 Damaged, improperly functioning product, missing or inaccurate
paper work, poor quality, late deliveries, or rework.

Overproduction
Converting material or information before it is needed by end user or downstream customer.
 It applies to WIP and finished goods.

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 DOWNTIME
Waiting
Person or machine idle due to lack of information or material required to continue operation.

Neglected Resources
Omitting, neglecting, ignoring or misusing the best resources available for the application at
the time.
 Not using the best talent, equipment, machines, or software.

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 DOWNTIME
Transportation
Unnecessary movement of product or information that does not add value to meet the customer’s
requirements.

Inventory
Material or initial information in a process queue.
 Raw material and Finished Goods

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 DOWNTIME
Motion
Unnecessary movement by people that does not add value to meet customer’s requirements.
 reaching, bending, walking or any other unnecessary movement.

Extra Processing
Producing and providing more features, information or work than what is required to meet
customer’s requirements. It includes extra steps done to meet customer requirements.

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 Mindset Organization culture ,
management
Lack of job training

Men/Women We've always done that !

Poor employee skills
“That’s good enough”

Lack of job rotation

Poor SOPs
Lack of scheduled
preventive maintenance DOWNTIME
Machines Methods
Wearing out tools /
(Defects) Ask operators what improves
machines processes

Improper calibration Defected material used

Materials
Incorrect measuring
. Material nonconforming to
device used Measurement Mother Nature Specs

Inconsistent measurements Cheap /inferior material used

with identical devices
Product not stand Improper Environ &
sunlight , heat, vibration surroundings

Humidity & moisture cause

degradation Improper environ for workers

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Lack of training in Lean

Improper staffing/ Just-In-Case rather

Men/Women than Just-In-Time
scheduling
Mindset
Workers set to Large batches to
fill up time reduce set-up

Lean tools like Pull,

Unreliable machines Kanban not used
overproduce until they fail

Machines DOWNTIME Methods

Old machines need (Overproduction)
replacement
Lack of process
standardization

Insufficient devices
cause flow restriction
Measurement Lot sizes require
overproduction

Inconsistent measurements Mother Nature

Materials Inflexible supplier
necessitate overproduction
to assure quality MOQ

Overproduce to replace Improper storage

Supplier doesn?t
spoiled products conditions
employ Lean

Improper layout leading Lack of roof/floor maintenance

to damaged products causing leaks and animals inlets

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 Overly cautious policies

Lack of trust amongst people

Men/Women
Lack of training causing Mindset Unnecessary steps
delay to proceed in work causing delays/idleness

Unnecessary approvals
to proceed

Lack of TPM cause Batch processing

machine failures cause delays in
Machines DOWNTIME downstream
Insufficient machines (Waiting )
to keep process move Methods Poor line balance
cause bottlenecks

Insufficient devices
cause process to stop Inferior material
cause delays/stops
Old/outdated
measuring devices Measurement Mother Nature Materials Material untimely
available

Long calibration time Undesirable weather Material nonconforming

Frequent blackouts conditions to Specs

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 Ignored job rotation and
cross -training
Training programs not in
pace with tech and policies
Lack of training on new
resources (e.g. s/w)
Lack of automation for time -
consuming processes
Compatibility glitches
b/w resources
Old version of s/w
on machines used
Good gauges lay idle in
storage
Mindset not
technologically friendly
Men/Women
Mindset Outside consultants while
talent exist in -house
Not utilizing newer
s/w or upgrades
Not on top of technology
Machines
DOWNTIME Methods Ignored better tech
(Neglected Resources)
Newer , more efficient
methods are rejected
Inferior material
lessens productivity
Measurement
Mother Nature Materials
Improper format /specs of
material received by resources
Environment prevents use Environment causes
of good resources good resources to fail
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 Products /WIP moved to
central staging area

No training on proper use

of material handling equip . Mindset Documents require
signature are hand -carried
No training on e -communication
Men/Women
instead of manual

Proper movement of
material /info not part of
SOPs
Improper alignment of machines Methods
in sequential production
Machines
DOWNTIME
(Transportation)
Each job is not supplied
with its necessary tools Material requires controlled
environ and transport

Volume of material delivered

Materials requires sorting and staging
Material moved to
measurement labs
Measurement Mother Nature
Material is bulky to be kept on site
Gauges fixed offsite
when they breakdown
Multiple emails sent can be
Inefficient disaster plan to keep Material moved to proper areas replaced with newsletter
equipment safe in bad conditions during improper conditions
Hand -carried info can be
transported electronically

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 Just-In-Case overrides
JIT thinking

Inadequate training on Lean Mindset Inaccurate material

to control inventory requirement forecast
Men/Women

Inventory control SOPs not

documented/followed
Machines authorized in batch
production causing excessive inventory

Machines with frequent

Machines
DOWNTIME Methods
Kanban not used to
communicate demands
breakdown requiring extra (Inventory)
inventory replacement
Inferior material
requiring quantities
more than needed
Inaccurate or non-
calibrated meas devices
Cause questionable rejects
Resulting in more inventory Measurement Mother Nature Materials Large MOQ from suppliers
more than needed

Unprotected material
damaged requiring
replacement inventory

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 Workers caused to search for
No training to perform jobs supervisors before they proceed
with minimal reaching,
bending, searching Unnecessary meetings
Men/Women Mindset
No workers involvement in Lack of ergonomics
workplace design practices adoption

Hand tools are used

instead of power tools Desks/workstations not
ergonomically designed

On/Off and emergency Machines DOWNTIME

Methods
switches not within reach (Motion)
Tools/materials not within
ergonomic reach of workers
Tools/supplies/printers not
within reach
Materials need preparation/
unwrapping before use
Measuring devices
require bending/
awkward positioning Measurement Mother Nature Materials WIP is not oriented to the
best reach of next operator

Meas. devices are not

enough to share Environ. Conditions cause
unnecessary motion; e.g.
scattered papers from wind

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Lack of training/
communication cause
duplicate process steps
Machining tolerances
more than customer needs
Tools/supplies cause workers to
perform extra steps to meet specs
Inconsistent measuring devices
cause additional work
Wrong measuring device
cause additional steps or
checking more frequently
Product shipped with
extra unvalued packaging
Mindset Product inspected by
someone other than worker
Men/Women
Inspection done at downstream
steps instead of source alone
No SOPs cause extra
polishing steps
Machines
DOWNTIME Methods
Not required packaging
(Extra Processing)
by customer
Inferior material require extra
preparation before use
Measurement Mother Nature Materials Documents contain more info
than needed to do a task
Forms ask for repetitive
info whenever used
Environ. Conditions cause extra
processing to make product conforming
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Case Study
Air-Cooled Chiller Assembly Process

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Case Study
Refrigeration Cycle of Air-Cooled Chiller

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 Case Study
What is required?

a) Study and understand the process.

b) Process-map the process
c) Identify the wastes in the process
d) Measure the waste
e) Identify the root cause of each waste type
f) Propose a preventive action to the root cause

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 Case Study
Process Analysis-Waste Template (example)
Activity Waste Type Measure Cause Root Cause Preventive Action

Bringing chiller design Motion 10min Machine Input material not Material: soft copies of drawings
paper drawings from within reach received via email
the Design section

Neglected Email/ Mindset not utilizing new tech Mindset: utilizing new tech
Resources software (email)

Transportation 30m Material Paper need to be Material: soft copies of drawings

carried from Design to received via email
Assembly

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