Continuous Improvement Workshop Training - PowerPoint PPT Presentation

1 / 15
About This Presentation
Title:

Continuous Improvement Workshop Training

Description:

The Seven Forms of Waste Continuous Improvement focuses on the identification and elimination of the 7 forms of waste: Overproduction Inventory Unnecessary Motion – PowerPoint PPT presentation

Number of Views:468
Avg rating:3.0/5.0
Slides: 16
Provided by: mcr67
Category:

less

Transcript and Presenter's Notes

Title: Continuous Improvement Workshop Training


1
The 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

2
1. 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

3
Waste Of Overproduction Example
OPERATOR SHOULD BE IN THIS STATION (ST 16) BUT IS
WORKING AHEAD IN ST 15
4
2. 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  • excess WIP and finished out-of-date product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

5
Excess Inventory Example
STANDARD SET AT 4 HIGH X 3 DEEP
PART BIN STACKED 6 HIGH
6
3. 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

7
Waste of Motion Example
TEAM MEMBER IN PAINT SHOP ATTEMPTING TO UNTANGLE
HOSES TO THE BACK-UP GUNS IN THE TOP COAT BOOTH.
8
4. 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

9
Waste of Transportation Example
BODY SHOP CONVEYANCE DELIVERS AMS BRACKETS TO
TABLE ON THE FLOOR
BODY SHOP T/M CARRIES PARTS TO RACK LINESIDE.
10
5. 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

11
Waste of Waiting Example
TEAM MEMBER WAITING ON BODY IN ST. 3900. ROBOTS
IN ST. 2400 WENT DOWN CAUSING DOWNTIME
12
6. 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

13
Waste of Over Processing Example
BODY SHOP T/M SANDING DOOR THAT HAD NO DEFECTS
14
7. 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

15
Waste of Repair Example
PAINT SHOP T/M MAKING REPAIR IN SPOT REPAIR BOOTH.
Write a Comment
User Comments (0)
About PowerShow.com