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Training:

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7 Waste
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here Global R&D Lab here
Company name - 1 -
11/13/2017
CP3
7 Wastes

Process flows with NO WASTE


Waste - activities that do not add value to a product from the
customer point of view
Waste increases product cost and lead time

7 Types of Waste - Waste is group into seven major


categories described below
Overproduction Production Defects
Waiting Inventory
Transportation
CP3 ZAZ WP3: ConFlow - 2 -

Over-Processing
Motion
First Waste
Waste of Overproduction

Considered the most significant source of waste.


Means producing more, sooner or faster than required.
Source of the following cost items:
Excess inventory
Equipment & people to handle, sort Material shortages
Capacity limitation (labor & equipment)
Hides quality problems
Money tied up in inventory
Effort to store batches
Storage space
CP3 ZAZ WP3: ConFlow - 3 -

How to Fix it
Implement Flow
Seven Wastes
Waste Overproduction

We already have
a lot of parts Thats okay
QTY

QTY

Capacity
Used

Demand

Excess Inventory
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Second Waste
Waste of Waiting

Idle time between operations or during and operation


Typical root causes are:
Missing material
Unbalanced line
Scheduling mistake
Im waiting for
parts
CP3 ZAZ WP3: ConFlow - 5 -

Process 1 Process 2
Third Waste
Waste of Transportation

Transportation waste is moving material more than


necessary

Typical root cause is:


Poor lay-out
Validate! Thats in
the next building

8) Pack
9) Validate
10) Outbound
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Fourth Waste
Waste of Motion

Motion waste is any motion, which is not necessary to


the successful completion of an operation
Some common forms of this waste are:
Back-and-forth movement in a workstation
Searching for parts
Searching for tools
Changes in the position of worker Part A Bin

Step 11:
Add
Part A Part A Bin
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Fifth Waste
Waste of Production Defects

This entails producing defective goods or mishandling


material
Some common forms of this waste are:
Rework of parts not made correctly in the first place
Productivity loss due to need of capacity to manage re-flow
Good, Bad, Good,
Good, Bad . . .

Waste
CP3 ZAZ WP3: ConFlow - 8 -

Good

Inspection
Sixth Waste
Waste of Inventory

Inventory waste is excess stock in the form of:


Raw materials
Work-in-process
Finished goods
5/9/96

Date
OEE
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Seventh Waste
Waste of Over-Processing

Over-processing means doing more than necessary


Most difficult to identify and eliminate
Intermediate testing or inspecting operations
Nice finishing in areas not visible
I put Part A on But I need to
first then Part remove Part A to
1 paint part 1
CP3 ZAZ WP3: ConFlow - 10 -

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