Title: Continuous Improvement Workshop Training
1The Seven Forms of Waste
- Continuous Improvement focuses on the
identification and elimination of the 7 forms of
waste - Overproduction
- Inventory
- Unnecessary Motion
- Transportation
- Waiting
- Over Processing
- Defects / Repair / Rework
21. Over Production
- Producing products or materials before they are
needed. - Overproduction is the worst form of waste because
it is the root cause of many other wastes. - Results of Over Production
- Products being produced in excess quantities
- Products being made before customers need them
- Excess Inventory
- Excess Transportation
- Hides available capacity
- Caused by
- Working ahead of customer (internal/external)
or process requirements
3Waste Of Overproduction Example
OPERATOR SHOULD BE IN THIS STATION (ST 16) BUT IS
WORKING AHEAD IN ST 15
42. Inventory
- Excess inventory is not directly required for
current customer orders. - Results of Excess Inventory
- requires space
- costs money and ties up capital
- search and transport damage
- hides defects
- excess WIP and finished out-of-date product
- Increased deterioration
- Caused by
- Working ahead of build requirements
- High WIP standards
- No WIP standards
- Lack of JIT/Pull system
5Excess Inventory Example
STANDARD SET AT 4 HIGH X 3 DEEP
PART BIN STACKED 6 HIGH
63. Motion
- Unnecessary movement in a process.
- Some Results of Motion
- unnecessary walking
- poor ergonomic conditions
- part transfer
- reaching and stopping and walking to locate/
pick up parts/tools - Caused by
- poor parts placement
- poor process flow
- poor work station layout
7Waste of Motion Example
TEAM MEMBER IN PAINT SHOP ATTEMPTING TO UNTANGLE
HOSES TO THE BACK-UP GUNS IN THE TOP COAT BOOTH.
84. Transportation
- The unnecessary movement of materials
- Results of Transportation
- Loss of traceability
- Damaged goods
- Increased Lead Time
- Excess Costs
- Storage space
- Caused by
- Poor parts storage
- Poor Work area layouts
- Working ahead of build requirements
- Lack of JIT/ Pull system
9Waste of Transportation Example
BODY SHOP CONVEYANCE DELIVERS AMS BRACKETS TO
TABLE ON THE FLOOR
BODY SHOP T/M CARRIES PARTS TO RACK LINESIDE.
105. Waiting
- Periods of inactivity in a downstream process
that occur because an upstream activity does not
deliver on time. - Results of Waiting
- Over Production
- Over Processing
- Idle resources
- Non-Value added work
- Caused by
- Line stops
- Waiting for Material
- Repair/Maintenance
- Waiting for equipment to process
- Missing tools
- Non- Full work process
11Waste of Waiting Example
TEAM MEMBER WAITING ON BODY IN ST. 3900. ROBOTS
IN ST. 2400 WENT DOWN CAUSING DOWNTIME
126. Over Processing
- Producing more or better than the customer
requires. - Results of Over Processing
- Increased Processing Time
- Costs
- Incorrect process/equipment
- Caused by
- Refining the product in ways or areas not
- important to the customer
- Wait Time
- Unclear Quality Standards
13Waste of Over Processing Example
BODY SHOP T/M SANDING DOOR THAT HAD NO DEFECTS
147. Defects/Repair/Rework
- Products or aspects of the production processes
that do not conform to specifications or to the
customers expectations. - Results of Defects/Repair/Rework
- Customer Dissatisfaction
- Non-Value added work
- Extra costs
- Extra space
- Extra inspections/checks
- Caused by
- Scrapped parts
- Wrong or defective tools or machines
- Wrong or missing processes
- Poor Problem Solving
- Unclear Standards
15Waste of Repair Example
PAINT SHOP T/M MAKING REPAIR IN SPOT REPAIR BOOTH.