ELIMINATION OF WASTE

1 KANZEN INSTITUTE
ASIA PACIFIC
 THE LEAN JOURNEY

Across the
Value Stream
SEE Waste

Within an operation

Find and analyze

root cause
Flow Layout
QMS

Apply solutions and

ELIMINATE waste Workstation
Point
Kaizen
Lean means a never ending WAR on WASTE
2 KANZEN INSTITUTE
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 What is MUDA?

Activity MUDA (Waste and + Work (Value

= Losses) Adding)
Set of
processes

Value Adding Activity Non-Value Adding Activity

A process step that transforms Process steps that take time,
the shape, property, resources, or space, but do not
characteristic or feature of a add value to the product or
product or service in the service and thus doesn’t add
direction specified by the value to customer
customer
Value addition is what the customer is willing to pay for !

3 KANZEN INSTITUTE
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 Value Add vs. Non-Value Add
The Good, the Bad and the Ugly ...
WORK
WORK
PROCESS
PROCESS

NORMAL ABNORMAL

VALUE NON-VALUE

te
ADDED ADDED

as
W
NECESSARY UNNECESSARY

FLOW REDUCE ELIMINATE

4 KANZEN INSTITUTE
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 OPERATIONS ANALYSIS TABLE

Operation: Cutout Punch Machine: 50T press

No. of operators: 2
S.No. Activity Time (s) Remarks (Muda/Muri/Mura)

1. Lift Sheet 3 Sheet sticking to each other at times

2 Move to press 3 Moving 10 feet, rotating sheet 180 deg
3 Position 5 Adjusting to match stopper
4 Press Button 2
5 Punch 5 Value adding
6 Remove sheet 2
7 Place on table 3 Moving 8 feet

Total VA time 3
Total cycle time 23 VA ratio is 13%

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 Analysis: Root causes (Why-Why)

Problem Why Why Why Why Why Solution

Position One side Interfering No Modify design and

adjustment stopper with provision make new die
not fixed current die made in
stroke die design

Movement Table for Allow Direct feeding to

to place next space for bending press
sheet after process next avoiding extra
punching located at process – storage and
the back. sheet held handling
in length
for bending

6 KANZEN INSTITUTE
ASIA PACIFIC
 The Gemba Principles

Go to Gemba - When an abnormality occurs

Check Gembutsu - Machine, Material, Failures, Rejects etc.

Search for - Muda (waste), Mura (inconsistency), Muri (physical strain)

Speak with data - Take temporary countermeasures on the spot

Make KAIZEN® - Remove root causes

Standardize - Standardize to prevent recurrance

7 KANZEN INSTITUTE
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