What is Muda Mura Muri in Lean Manufacturing?
→ The 3M technique in Lean Manufacturing is mostly used in the Toyota Production System.
→ The 3M stands for Muda, Mura, and Muri. This is a Japanese Concept.
→ The goal of Lean Manufacturing is to deliver increased value to the customer with the help of eliminating all kinds of wastes from processes.
→ Now we will understand this concept with the help of examples and case studies.
What is Muda?
→ Muda means waste or we can say that any activity that consumes resources but not creating value for the organization or customer.
7 Types of Muda (Wastes) In Lean Manufacturing
→ The 7 types of Muda in lean manufacturing are mentioned below.
→ Refer to this article for a detailed presentation with the infographics of 7 Types of Wastes in Lean Manufacturing.
→ Nowadays one more waste is added into muda that is un-utilized talent or skill set.
- Transportation
- Inventory
- Motion or Movement loss
- Waiting
- Overprocessing
- Overproduction
- Defective Parts
→ We can eliminate all these wastes with the help of Various Kaizen Activities.
What is Mura?
→ Mura means unevenness in any process or schedule.
→ Unevenness can be eliminated by Line Balancing or Level Scheduling for any process.
→ We can also say mura means variation or fluctuation in any process.
→ Sometimes there are many fluctuations in product demand so it will directly reflect on the production planning fluctuations. This is the very basic example of Mura.
➨ Refer to the below basic examples of Mura
⇢ Uneven Customer Demand
⇢ Uneven Production Speed
⇢ Uneven Work Load Distribution
⇢ Product Quality is not consistent
What is Muri?
→ Muri means overburden on the equipment or on the person.
→ In other words, we can say that if we are running equipment on a higher load for a long time that is called overburden or muri.
→ Also, if we tell the operator to work long period of time without taking any breaks that are also overburdened.
→ We can see this kind of wastes when the product demand is increased at that time machine and operators are working on overburden like in extra shift.
→ So it will create the problems like breakdowns, defect generation, etc.
➨ Refer to the below basic examples of Muri
⇢ Working in overtime or for a longer time due to uneven customer demand
⇢ Noise level is very high in the working area
⇢ The machine is running out of capacity due to high customer demand
⇢ Overloading of truck
Example of Muda Mura Muri Wastes:
→ Let us take one real-life example for understanding this concept.
→ One logistic company needs to transport 6000kg of material from Location A to B.
→ So there are many transportation scenarios that are possible, out of that we will take three different cases for understanding the concept.
Case 01:
→ Transportation company load 6000kg material in a truck and make a single trip.
→ But the truck's load caring capacity is 3000kg.
→ So it is Muri types of waste. It is overburdened on the truck.
→ So truck might be leading to breakdowns.
Case 02:
→ We can take a second case If the truck makes two trips of 2000kg in the first trip and the second trip of 4000kg.
→ This is the case of Mura because there is the unevenness of materials arriving at the destination location.
→ Due to the unevenness of material sometimes it creates problems of handling and storage.
→ Also, it is an example of Muri - overburden on an operator to multiple time loading and unloading activity need to do that is due to two trips instead of a single trip.
→ So these wastes are not adding any value to the supplier or customer.
Case 03:
→ In the third case, we make three trips of loading 2000kg material on a single trip.
→ So this is an example of underloading of trucks.
→ So it is a Muda means waste.
→ The only way to eliminate all types of waste we need to arrange two trucks having a capacity of 3000kg and make two trips of 3000kg each.
How to eliminate Muda, Mura, Muri Wastes?
→ We can use below various Lean Manufacturing tools for eliminating all Muda, Mura, and Muri wastes.
Im learning too much from you guys. Thanks
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