Skip to main content

Lean Management – Types of Waste

The Main One
→Transportation →Inventory →Motion →Waiting →Over-production →Over-processing →Defects
Transportation
√ Definition: Any movement of materials, supplies or resources that does not add value to the internal or external customer needs
√ Characteristics
• Extra carts, fork lifts
• Multiple storage locations
• Complex inventory management
• Extra facility space
• Improper facility layout

 Inventory
√ Definition: Any supply in excess to process requirements necessary to produce goods or services just in time
√ Characteristics
• Material between processes
• Additional material handling resources
• Additional investment / cost
• Storage space
• Perishable, damage and obsolescence
• LIFO instead of FIFO
Motion
√ Definition: Any movement of people, resources or machines which does not contribute/add value to the product or service
√ Characteristics
• Human motion
• Lack of visual controls
• Looking for tools
• Material too far apart (walk time)
• Machine motion
Waiting
√ Definition: Long period of inactivity for people, machine, or material waiting for each other
√ Characteristics
• Improper scheduling
• People waiting for machine or resources
• Poor material planning
• Late Deliveries
• Unbalanced operations
Over-Production
√ Definition: Producing faster or excess quantity than the internal or external customer needs
√ Characteristics
• Just-in-case reward system
• Large lot size batch processing
• Improper demand planning/Unbalanced material flow
• Producing early
• Inventory stockpiles
Over-Processing
√ Definition: Effort which adds NO value to a product or service. Enhancements which are not valued by customers.
√ Characteristics
• Lack of clear customer specifications
• Endless refinement
• Redundant approvals
• Extra copies or excessive information
Defect
√ Definition: Rework needed to rectify the defect in product or service to fulfill customer requirements
√ Characteristics
• Quality problems
• Extra resources to inspect/test/rework
• Insufficient training
• Inconsistent work methods, tools
• Excessive variation

Other type of Waste
Underutilized Skills
Wrong Use of Automation
Wrong Use of Metrics

Underutilized Skills
√ Definition: Any skill that is not utilized to its full potential leading to customer value
√ Characteristics
• Skills based compensation
• Over qualification
• Under performance
• Morale
Wrong Use of Automation
√ Definition: Any automation that is taking longer than manual work or creating additional work
√ Characteristics
• Over automation
• Under automation
• Unnecessary automation
• Automation defects/rejects
• Examples
Wrong Use of Metrics
√ Definition: Any metrics that is incorrectly measured, inappropriately used or misinterpreted is another type of waste
√ Characteristics
• Incorrect data collection
• Inappropriate use
• Misinterpretation
• Misaligned targets or goals
• Examples

Summary
√ Seven Main Types of Waste
√ Other Types of Waste


To Be Continue

Comments

  1. AshwiniJune 28, 2021 at 6:01 AM

    very informative post .Thanks for sharing post
    Jost’s Material Handling provides innovative solutions for internal material handling needs for its customers so that it improves the efficiencies of their processes.
    material handling
    PIV
    Constant Temperature Anemometry

    ReplyDelete

Post a Comment

Popular posts from this blog

H&M SUPPLIER COLOR GUIDELINE

H&M has established this Colour Guideline to guide suppliers to achieve a quicker and better result in their colour work. For H&M Cosmetic products a separate Colour Guide Book is available. The guidelines and requirements in this Colour Guideline apply to all products in textile, leather/suede, plastic, bone, wood, metal, straw, paper etc. Colour evaluation using instrumental method should be used when applicable. All parts of a product are equally important to check according to the same guidelines; shell, details, accessories (including: threads, buttons, badges, zippers, interlinings, drawstrings, stoppers) etc. Therefore these guidelines are made for everyone involved in the colour process – garment makers, accessory suppliers, dyers, print houses, embroidery units etc. Each supplier to H&M is responsible for informing all of their suppliers and subcontractors about the content of these guidelines and requirements and to make sure that they al...
2 comments
Read more

How Can Improve Production Quality

To become quality conscious, it might look at improving existing quality standards at various stages of manufacturing process. Producing a good quality product is a result of combined efforts of management, employees and workers by developing system, implementing good practices in floor and setting up standards.  Following tips can help to improve quality at production. Communicate the importance of quality production to your employees and floor workers, and explain quality expectations by the management.  Maintain a clean and dry workplace, including storage rooms and shipping areas.  Select and utilize appropriate equipment in cutting, sewing and finishing processes.  Provide appropriate tools, machines and equipment to each department. Provide on-the-job training to workers for new comer with existing.  Plan an ongoing program for machine maintenance.  Establish agreed-upon quality standards with all fabric ...
1 comment
Read more

Cutting Quality Control & Re-cut procedure.

Cutting Quality Control: To be established a work process by which QC personnel able to run in a same path for continuous improvement.  The procedure can be control / feedback to cutting to produce smoothly & Good Quality production. Responsibility :  The responsible person in-charge of related department. Preparation for Bulk cutting: v   According cutting plan cutting Executive collects Approved sample, manufacturing order sheet, approved paper pattern / hard pattern & Marker paper with ratio chart. v   As per Order Qty. cutting Executive collects fabrics from WH & relaxes the fabric according estimated time. v   QA checks between ratio paper, marker paper, hard pattern & fabric inspection report. He confirms the marker with signature. v   QC makes mock up by style related parts to be check & ensure parts Shading. If have taken approval from Quality Manager or Merchandiser. v   According cutting plan ...
Post a Comment
Read more