Seven

Seven wastes
wastes

By K.MARIAPPAN
 WASTE
• TOYOTA defines Waste as: "anything other than the
minimum amount of equipment, materials,parts, and working
time absolutely essential to production."

• The mission of LSPS is to eliminate waste to improve

productivity.

• Simply we can remember the Seven Wastes by using the

acronym "TIM WOOD"
7 Types of wastes

Transport
Inventory
Motion
Waiting
Over Production
Over Processing
Defects
 Motion

Over -Processing
Taiichi Ohno’s 7 Wastes

Over - Production
TEN CALL IT How do you spell that?
PLEASE! TWENTY?
…22 TO BE ON
THE SAFE SIDE!

KODAK OPE RATING SYSTEM

KODAK OPERATING S YSTEM

Defects / Rejects / Re-work
KODAK OPERATING SYSTEM

Waiting Inventory
$
$$
$$ $
Transportation
$ $ $
KODAK OP ERATING SYSTEM
$

$ $

KODAK OPERATING SYSTEM

KODAK OPERATING SY STEM

KODAK OPERATING SY STEM

 Over
Over
Transport Inventory Motion Waiting proce Defect
prodn
ssing

Transport waste :

• Unnecessary Transport of materials

• In moving products between factories, between work

centres, between desks, between machines, all that is

added is lead-time – no value is created.

Tra
 Over
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Transport Inventory Motion Waiting proce Defect
prodn
ssing

• Transport Waste is only eliminated through removing its

sources.
• In general, these are in fact Inventory Wastes, which due
to their pervasive nature, are hard to see or eliminate.
• In general, these are tackled through a slower-burn version
of kaizen, often lasting a few months.
• The nature of Transport Waste is such that it often
crosses departmental boundaries (following the value
stream).
• To eliminate its sources therefore requires cross-
departmental teams.

Tra
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Transport Inventory Motion Waiting proce Defect
prodn
ssing

Inventory Waste:

• Inventories beyond the absolute minimum

• Caused by overproduction, inventories take up floor space –

something that is always at a premium in factories and

offices. There's always a dendancy to use inventories to

mask other problems. Remember, if you've got pleanty of

Inventory
spares, there's no incentive to fix problems with quality! $
$$
$$ $
$ $ $ $
$ $

KODAK OPERATING SYSTEM

 Over
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Transport Inventory Motion Waiting proce Defect
prodn
ssing
• Significant amounts of Inventory Waste exist in almost all
processes.

• These can usually be significantly reduced through a

concerted, short-term project.

• In this, a team including those who actually run the process,

technical experts, lay-persons, and a facilitator expert plan
and implement changes within a week.

• This is often called a “Kaizen Blitz”, or “kaikaku” from the

Japanese terms for such shop floor-led improvements.
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Transport Inventory Motion Waiting proce Defect
prodn
ssing

Motions waste :

• Motions of employees

• Looking for parts, bending / reaching for materials,

searching for tools, etc.

Motion

KODAK OPERATING SY STEM

 Over
Over
Transport Inventory Motion Waiting proce Defect
prodn
ssing

Waiting waste :

• Waiting for the next process step.

• While waiting, the product is just soaking up ‘overheads’ –

the last thing that the customer actually wants to pay for!

Waiting

KODAK OPERATING SYS TEM

 Over
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Transport Inventory Motion Waiting proce Defect
prodn
ssing

Over Production waste :

• Overproduction ahead of demand.

• This exposes the organisation to risks in changing demands

from customers, and is a disincentive to the firm to reduce

the other wastes, since there’s always plenty of extra material

Taiichi Ohno’s 7 Wastes

Over - Production
to use in case of problems. TEN CALL IT
PLEASE! TWENTY?
…22 TO BE ON
THE SAFE SIDE!

KODAK OPERATING SYS TEM

 Over
Over
Transport Inventory Motion Waiting proce Defect
prodn
ssing

Over Processing waste :

• Overprocessing of parts

• Running parts on machines that are too fast / too slow, or

even too accurate to achieve the customer’s definition of

Value. What's the problem with doing too good a job? Well

generally it means too expensive a job for the market's

Over -Processing

expectations. How do you spell that?

KODAK OPERATING SY STEM

 Over
Over
Transport Inventory Motion Waiting proce Defect
prodn
ssing
Defect waste :
• Producing Defective parts

• If processes produce defects, then extra staff are needed

to inspect, and extra materials needed to take account of

potential losses. Worse than this, INSPECTION DOES NOT

WORK. Eventually you'll miss a problem, and then send a

defective product to a customer. And they WILL notice, at

which point, all hell will break loose! Defects / Rejects / Re-work

KODAK OPERATING SY STEM

Things to be consider. . . . .

• When you're trying to figure out if you're looking at Transport

Waste, or Inventory Waste, it's useful to remember that there
are only three basic reasons for waste being unavoidable.
• The laws of physics. It would be great to speed things up by
using magic, but that's sadly not possible!
• The laws of the land. You could reduce machine set-up time by
removing all the safety guards, but killing your staff is illegal.
• Outright cost. Got a 20,000 ton press in the wrong location?
You're probably going to have to live with that kind of problem