8 Wastes of Lean Manufacturing

8 Wastes of Lean Manufacturing

→ 8 Wastes of Lean Manufacturing are Transportation, Inventory, Motion, Waiting, Overproduction, Over-processing, Defects, & Skillset or Non-utilized talent.
The acronym we can say as TIMWOODS or DOWNTIME.
➨ DOWNTIME
     ⇢ D = Defects
     ⇢ O = Overproduction
     ⇢ W = Waiting
     ⇢ N = Non-utilized Talent
     ⇢ T = Transportation
     ⇢ I = Inventory
     ⇢ M = Motion
     ⇢ E = Extra processing
➨ TIMWOODS:
     ⇢ T = Transportation
     ⇢ I = Inventory
     ⇢ M = Motion
     ⇢ W = Waiting
     ⇢ O = Overprocessing
     ⇢ O = Overproduction
     ⇢ D = Defects
     ⇢ S = Skill Set



What is Waste in Lean Manufacturing?

→ In simple language, It is something that adds no values.  or
→ "Our customers would not be happy to pay for any action that we take is called waste"
→ People usually, only think about all of the scrap material that gets thrown away. They often forget about all of the other actions that waste our time, our resources and our money.
→ Would you want to pay for the machine operators wages while :
    ⇢ They sat idle waiting for a delivery,
    ⇢ For the rework processes that had to be undertaken because the machine was incorrectly set or
    ⇢ Even for storing your product for three months before it was delivered to the store?
→ These all activities are included within the cost of your products, either inflating the price you pay or reducing the profit of the company.

Eight Wastes in Lean Manufacturing [TIMWOODS]:

  1. Transportation
  2. Inventory
  3. Motion
  4. Waiting
  5. Overproduction
  6. Over-processing
  7. Defects
  8. Skills sets (non-utilized talent)



Eight Wastes of Lean Manufacturing

[1] Transportation waste in Lean Manufacturing:

→ Transportation waste in Lean Manufacturing is not adding any value to the product and it directly impacts your financial indicator and it can be a very high cost to your business, you need people to operate it and equipment such as trucks or forklifts to undertake this movement of materials.
→ Transportation is the movement of materials from one location to another and it does not add any value to the product.
→ Your customer is not willing to pay for that.
→ Transportation adds no value to the product and you are paying people to move material from one location to another so this is not good for the organization.

Transportation

Examples:

→ Sending unsold products from the store to the warehouse back.
→ Ordering parts or products from distant suppliers when closer options are available.
→ Moving parts from one station to another.
→ Moving equipment from one construction site to another.


[2] Inventory:

→ Every piece of product tied up in raw material, work in progress or finished goods has a cost and until it is actually sold that cost is yours.
→ Inventory has to be stored, it needs space, it needs packaging and it has to be transported around.
→ It has the chance of being damaged during transport and becoming obsolete.

Inventory

Examples:

→ Too much Raw material, work in progress (WIP), and too much finish goods (FG).
→ Inventory of extra spares and machines in ideal condition.
→ All inventory should be optimum and minimum.

[3] Motion Waste in Lean Manufacturing:

→ Unnecessary movements of man or machine which do not add any value in the product are known as motion waste.
→ Excessive machine movements from the machine start point to actual work start point.
→ All of these unnecessary motions cost you time (money) and cause stress on your employees and machines.
Motion

Examples:

→ Software that requires 10 clicks to start.
→ Workers searching for missing tools or instruments.
→ Excessive travel between workstations.



[4] Waiting:

→ Waiting for a delivery from a supplier or an engineer to come and fix a machine?
→ We have to spend a huge amount of waiting time for things in our working environment.
→ People and processes often must wait because the next step in the process isn’t ready for them yet so it is waste.

Waiting

Examples:

→ Emergency room patients waiting for test results in a hospital.
→ Farmer is waiting for water for the crop and airplane for a gate to open up

[5] Over Production:

→ If we have manufactured any X products and the customer does not want it now that is called Over Production or if the customer wants product X - 500 Nos and we manufacture 550 in that case 50 extra pieces are Over Production.
→ This is usually because of working with oversize batches, long lead times, poor supplier relations and a host of other reasons.
→ Overproduction leads to high levels of inventory which mask many of the problems within your organization.
→ The aim should be to make only what is required when it is required by the customer, the philosophy of Just in Time (JIT) or Continuous Flow (Single Piece Flow) however many companies work on the principle of Just in Case! (JIC).

Over Production

Examples:

→ Production is more than customer demand.
→ Huge meals in restaurants.
→ Hospitals with more beds than the community needs.
→ Overstaffed retail stores



[6] Over Processing:

→ Over-processing is doing more than the customer wants and give money for the product or service.
→ Sometimes Over Processing waste generates due to inappropriate techniques, oversize equipment, working to tolerances that are too tight, perform processes that are not required by the customer and so on.
→ All of these things cost us time and money.

Over Processing

Examples:

→ If Microsoft Excel is enough for us and we go for mini-tab for calculation.
→ Another example: X-ray is sufficient and we go for an MRI.
→ If the lathe machine is sufficient for operation and we are doing the operation with the CNC machine.
→ Complex purchasing processes with multiple approval levels.
→ One of the best examples for over processing is before sending mail to the manager we read twice or thrice.

[7] Defects:

→ Defects hide many other problems and wastes.
→ Quality errors that cause defects invariably cost you far more than you expect.
→ Every defective item requires rework or replacement, it wastes resources and materials, it can lead to lost customers.
→ We have to work on defect prevention instead of defect detection.
→ Implementation of Poka-Yoke systems and automation can help to prevent defects from occurring.
→ We can use Jidoka/Autonomation for defect preventing purposes.
→ We also implement standard operations procedures (SOP) and training to ensure that the correct methods are undertaken and standards achieved.
→ The defect is directly related to the Cost of Poor Quality.

Defects



Examples:

→ Software with bugs is a defect that has to be re-coded.
→ Misdiagnoses in healthcare that lead to unnecessary tests or treatment.
→ Products that are shipped to the wrong address is also a defect.
→ Manufactured items that don’t meet the customer’s specifications is a defect.

[8] Skill-Set (non-utilized talent):

→ Skill-set or non-utilized talent is newly added waste in Lean Manufacturing and it costs you money.
→ Not fully utilized people represents the waste of talent present in many organizations.
→ Because operators are close to their processes daily, they can often recognize problems or opportunities that staff or superiors just don’t see, but the workers may never be asked for their input.
→ They may also have outside talents that aren’t formally part of their assigned jobs but could be of use.
→ The recommendation? Value people for their brains, not just their brawn.

Examples:

→ Intentionally we are not including any competent employee or any department or section is also an example of non-utilized talent.
→ If we do not give our workers any chance for process improvement or any suggestion about improvement is also comes under skillset waste.

Benefit:

→ It Improves efficiency and effectiveness
→ Increase the productivity of production processes
→ It will increase the performance of plant indicator OEE (Overall Equipment Effectiveness)
→ It creates a safer working environment for all employees.
→ Reduce downtime

👉 Also Read:
      1. 5S Methodology



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