Waste

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(No Transcript)
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How Often Do We See These Scenarios in Our Work
Area?
Stocking Up Inventory
Equipment Breakdown
Excess Walking
Decision -Communication and Reporting Maze
Excessive Transporting,Storage Handling
Meetings, Meetings,Meetings!
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Definition of Waste

• Anything that doesnt add value to the product or
  service.
• Anything that doesnt help create conformance to
  the customers specifications.
• Anything your customer would be unwilling to pay
  you to do.

Non-Value Added Work
Use Different Pict.
Value Added Work
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Enemies of Any Process
Three Enemies 7 Wastes (Muda), Unevenness
(Mura), and Overburden (Muri)
Visual to be more understandable to Team members
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7 TYPES OF WASTE
CURRENT THINKING
REQUIRED THINKING
Shift Mindset
Correction
Processing

C
P
Over Production
Inventory
TYPES OFWASTE
O
I
WASTE
M
W
M
Motion
Waiting
Material Movement
WASTE NOT DEFINED REACT TO LARGE
EXAMPLES REACTIVE IMPROVEMENT
WASTE IS "TANGIBLE" IDENTIFY MANY SMALL
OPPORTUNITIES LEADS TO LARGE OVERALL CHANGE
CONTINUOUS IMPROVEMENT
Waste Elimination is the most Fundamental
component of Lean Manufacturing
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Correction
Elimination of Waste (contd) Ø          Waste of
Correction v        When a job is not done
correctly, extra time and money are used to
repair defects. v        The extra cost of labor
and materials is referred to as Waste of
Correction. v        All repair activities are an
opportunity to eliminate waste.
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Over Production
Support by Practical Examples
Elimination of Waste (contd) Ø          Waste of
Over Production v        This is the worst type
of waste and leads to the other six
types. v        The waste caused by producing
more goods than are necessary or by producing
goods at a rate faster than they are needed is
called Waste of Over Production. v        This
waste is a problem because it leads to extra cost
for materials, transportation, warehousing,
staffing, and energy. v        Working ahead on
the assembly line only to wait later to work is
another example of waste of Over Production.
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Waste of Overproduction Example
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Motion
Elimination of Waste (contd) Ø          Waste of
Motion v        Is any Team Member movement
which is not necessary for the production
process. v        An example of Waste of Motion
is the extra footsteps that a Team Member takes
at a poorly laid-out Workstation or when the
Standardized Work sequence is not planned or
followed.
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Waste of Motion Example

• Excess movement reaching for parts

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Material Movement
Elimination of Waste (contd) Ø          Waste of
Material Movement v        Is any movement of
material, which is not required for
production. v        This type of waste includes
any moving or rearranging of materials or double
handling of parts that does not add value to the
product. v        An example of this waste is
when a Team Member moves a part out of the parts
bin to a temporary storage area and returns later
in the operation to move the part to the job.
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Waiting
Elimination of Waste (contd) Ø          Waste of
Waiting v        Is an unproductive use of time
because it does not create or add value to the
Production Process. v        Can include waiting
between operations, waiting for an automatic
machine to finish, or waiting while the line is
down.
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Waste of Waiting Example

• 2nd Operator Waiting for 1st Operator to Perform
  Function

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Inventory

• Elimination of Waste (contd)
• Ø          Waste of Inventory
• v        This refers to inventory that sits
  between operations or inventory that is delivered
  by outside suppliers before required.
•     The elimination of this waste contributes to
  the Lean Material motto Provide material when it
  is needed by the customer and in only the
  quantity that is required by the customer.
•      Inventory that does not meet actual
  scheduled needs will result in extra cost and the
  use of valuable floor space.
•      Waste of Inventory makes First In First Out
  (FIFO) difficult to maintain.

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Waste of Inventory Example
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Excess Inventory Hides Problems !! Excess
Inventory Hides Waste !!
Your Company
Inventory (Buffer) Level
Water Inventory
Long Changeover
Equipment Downtime
Supplier Problems
Large Lot Sizes
Variation
Poor Layout
Rocks Problems (Opportunities)
Buffered organisations are lazy and have large
cushions - waste is Hidden Lean organisations
only use what is needed and make waste Visible!
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Processing
Elimination of Waste (contd) Ø          Waste of
(Over)-Processing v        This occurs when more
effort goes into an operation than is actually
required. v   Examples of Waste of Processing
are      A Team Member polishing the underside
of a trunk lid. The customer does not require
this activity.      A Team Member clicks a
torque wrench twice when one time is sufficient
as determined by the quality standards. Other
examples which are out side the shop floor for
new Team members
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What is the worst form of Waste???
Put Slide on Over production explain why it is
the more worst form of waste
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Waste is the Root Cause of Our Problem
7 Types of Waste
These are the biggest contributors to Higher Cost
(COMMWIP)

• C orrection (
• O verproduction
• M aterial Movement
• M otion
• W aiting
• I nventory
• P rocessing

GM is a High Cost Producer
We All Need to Actively Build a Lean, Low Cost
Culture
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Waste IdentificationGM PAC Video
Group Discussion between Round 1 and Round 2
What can be improved?
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Elimination of Waste
Arrange an competition for all TMs for
converting COMMWIP to HINDI so that the word can
be easily remembered pronounced .
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Correction - Sudhar Over Production - Jaroorat
se jyada utpadan Motion Chalna Material
Movement - Waiting Intazaar karna Inventory
Processing