What is waste?
any activity that consumes resources such as time, space, and materials, but does not add value to a product or service
Customers may not be willing to bear the ___________ of activities that don’t add __________ to them.
cost, value
What are the types of waste?
D - defects
O - overproduction
W - waiting
N - not utilizing knowledge, skills, and abilities
T - transportation
I - inventory
M - motion
E - excess processing
What is overproduction waste?
producing items earlier or in greater quantities than what is required, which results in too many finished goods in inventory or too many service providers waiting to deliver services
What are the causes of overproduction? (5)
- fear of insufficient inventory
- unbalancing scheduling or workload
- misuse of automation
- redundant systems
- creating buffer inventory to compensate for unreliable processes
What are the impacts of overproduction? (4)
- large-batch processing
- other types of waste (movement, transportation, inventory, waiting)
- confused priorities
- extra space needed
What metric is used to analyze overproduction?
Work in Progress (WIP)
What are defects?
process activities or outputs that do not conform to customer requirements
What causes defects? (7)
- unclear work instructions
- lack of standard work
- insufficient processes
- poorly maintained processes
- poor materials
- inadequate training
- lack of understanding of customer requirements
What is the impact of defects? (5)
- unnecessary rework
- inspections
- errors of omission
- costs to resolve issues
- potential loss of customer confidence
How are defects measured?
evaluation process to identify defects
How are defects analyzed?
defects/unit = number of defects/ number of units
first pass yield = # defect free units produced :# of units entering without requiring rework or scrap
What is waiting waste?
any time a work in progress is idle
What are the causes of waiting waste? (10)
- bottlenecks
- uneven cycle times
- information and queuing delays
- late deliveries
- upstream quality issues
- handoffs
- approvals
- inspections
- unplanned downtime
- producing forecast
What are the impacts of waiting? (2)
- downtime cost
- other types of waste: overprocessing, not utilizing knowledge, skills, abilities
What is transportation waste?
excess transport of information, products, or materials around the organization or between facilities
What are the causes of transportation waste? (3)
- poor workspace layout
- unclear understanding of process workflow
- excessively large storage areas
What are the impacts of transportation waste? (4)
- redundant handling of materials or products
- longer lead times
- damaged products
- added costs for transportation systems
What is inventory waste?
a supply in excess of single-piece flow is present in a process
What are the causes of inventory waste? (6)
- push system
- fear of insufficient quantities
- unbalanced scheduling or workloads
- incentive programs for exceeding production quotas
- poor market forecasts
- unreliable market shipment
What are the impacts of inventory waste? (4)
- extra costs in workers, time, space and finances
- additional wastes hidden by inventory
- obsolescence and damage
- shortages (due to lack of accurate info)
What is motion waste?
when people or outputs are diverted out of the flow of the system, adding movement without value
Efficiently designed systems are ___________________ and _______________________ strain and disruptions to safety, quality, and productivity.
ergonomic (designed for efficiency and comfort for users)
minimize
What are the causes of motion waste? (5)
- unfavorable work area layout
- poor organization and housekeeping
- inadequate instructions or documentation
- inconsistent work methods
- busy movements while waiting
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Continuous Improvement Fundamentals64
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Problem Solving Methods - DMAIC26
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Problem Solving Methods - PDSA13
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Problem Solving Methods - DFSS, DMADV & IDOV27
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Team Roles & Responsibilities17
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Organizational Communication + LSS Team10
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Team Collaboration46
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Team Ideation Tools11
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Team Communication27
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Process Analysis51
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FMEA15
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Waste Analysis33
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Lean Concepts20
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Waste Elimination41
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Value Stream Mapping18
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Kaizen19
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Project Set-Up28
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Project Management41
