7 Type of Wastes - TIMWOOD

of Lean Manufacturing
- 5S BalaMurugan
 The seven wastes are categories of unproductive manufacturing practices
identified by Taiichi Ohno, the father of the Toyota Production System.
 The categories are an integral part of the TPS / Lean production.
 Simply we can remember the Seven Wastes by using the below acronym.
5S BalaMurugan
https://www.linkedin.com/in/tqmbala/ tqmbala@gmail.com
 Transportation
 Inventory
 Motion
 Waiting
 Over Production
 Over Processing
 Defects
1
 Unnecessary movement of people or parts between processes.

 Moving a product between manufacturing processes adds no value, is
expensive and can cause damage or product deterioration.
Example :
 Moving hospital patients from department to department
 Sending overstocked inventory back to a warehouse or an outlet store location
 In software, it may mean moving code from one server or repository to another
 Transportation of products from one functional area to another
5S BalaMurugan
Over Over
Transport Inventory Motion Waiting Defects
production processing
2
 Excess products / materials (raw material, work in progress) not being

processed.
 It leads costs of storage and maintenance.
Example :
 Excess production of promotional materials or printed forms
 Produce or food that goes to waste in our kitchen
 Kitchen gadgets that are accumulated and not used
 Unused or rarely used equipment
5S BalaMurugan
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3
 Unnecessary movement of people, parts or machine within a process.

Example :
 People searching for materials, tools or equipment
 Handoffs in software development
 Poorly structured or disorganized work spaces
 Having to make too many clicks in a website or software to accomplish a small
task
5S BalaMurugan
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4
 Parts or people waiting for processing to be completed.

Example :
 Patients in waiting rooms
 Waiting for responses from other departments
 Manufacturing processes waiting for component delivery
 Waiting for a flight that's been delayed due to maintenance being done wrong
5S BalaMurugan
Over Over
https://www.slideshare.net/BalaMurugan272
5
 Manufacture of products in advance or in excess of demand wastes money,

time and space.
Example :
 Production of components before the next stage in the process is ready to
receive them
 Printing and filing of unnecessary documents
 Creation of meals that are not eaten or partially eaten
 Cars that sit unsold in a car dealer lot
5S BalaMurugan
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6
 Processing that exceeds the level required to meet specification.

Example :
 Entering the same data in more than one place on a form or in a
software application
 Multiple approval levels for a small spending request
 Ordering unnecessary tests for patients
 Extra report information
5S BalaMurugan
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7
 Efforts caused by rework, scrap and incorrect information.

Example :
 Scrap produced by poorly maintained fixtures
 Parts assembled with the incorrect orientation
 Incorrect components used due to incorrect, or missing instructions
 Poorly made components that continued to be made as the employees
wanted to reach their performance bonus
 Faulty parts that have reached the customer
5S BalaMurugan
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8
Some people have added an eighth waste to Ohno's original list.
As a result, the 8 wastes are commonly referred to as ‘TIMWOODS’.
 The 8th waste is – Non-utilized Human Resources / Talent – The waste of not
using people to the best of their unique abilities.
Example :
 Employees spend time on tasks that do not add value
 Career development and planning is absent
 People with advanced skills do routine work
Skills
 Employee ideas for improvement are ignored
Over Over
For more Lean, TQM related training Materials…
- 5S BALAMURUGAN
BSc(CS).,MBA(TQM).,MA(PM&IR).,MSc(Psy).,
Lean Practitioner | Quality Management Trainer | HR Professional
https://www.slideshare.net/BalaMurugan272

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of Lean Manufacturing

 Unnecessary movement of people or parts between processes.

 Excess products / materials (raw material, work in progress) not being

 Unnecessary movement of people, parts or machine within a process.

 Parts or people waiting for processing to be completed.

 Manufacture of products in advance or in excess of demand wastes money,

 Processing that exceeds the level required to meet specification.

 Efforts caused by rework, scrap and incorrect information.

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