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The Seven Forms of Waste

The Seven Forms of Waste. Continuous Improvement focuses on the identification and elimination of the 7 forms of waste: Overproduction Inventory Unnecessary Motion Transportation Waiting Over Processing Defects / Repair / Rework. 1. Over Production.

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The Seven Forms of Waste

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  1. The Seven Forms of Waste Continuous Improvement focuses on the identification and elimination of the 7 forms of waste: • Overproduction • Inventory • Unnecessary Motion • Transportation • Waiting • Over Processing • Defects / Repair / Rework

  2. 1. Over Production • Producing products or materials before they are needed. • Overproduction is the worst form of waste because it is the root cause of many other wastes. • Results of Over Production: • Products being produced in excess quantities • Products being made before customers need them • Excess Inventory • Excess Transportation • Hides available capacity • Caused by: • Working ahead of customer (internal/external) or process requirements

  3. Waste Of Overproduction : Example OPERATOR SHOULD BE IN THIS STATION (ST 16) BUT IS WORKING AHEAD IN ST 15

  4. 2. Inventory • Excess inventory is not directly required for current customer orders. • Results of Excess Inventory: • requires space • costs money and ties up capital • search and transport damage • hides defects • excess WIP and finished out-of-date product • Increased deterioration • Caused by: • Working ahead of build requirements • High WIP standards • No WIP standards • Lack of JIT/Pull system

  5. Excess Inventory: Example STANDARD SET AT 4 HIGH X 3 DEEP PART BIN STACKED 6 HIGH

  6. 3. Motion • Unnecessary movement in a process. • Some Results of Motion: • unnecessary walking • poor ergonomic conditions • part transfer • reaching and stopping and walking to locate/ pick up parts/tools • Caused by: • poor parts placement • poor process flow • poor work station layout

  7. Waste of Motion: Example TEAM MEMBER IN PAINT SHOP ATTEMPTING TO UNTANGLE HOSES TO THE BACK-UP GUNS IN THE TOP COAT BOOTH.

  8. 4. Transportation • The unnecessary movement of materials • Results of Transportation: • Loss of traceability • Damaged goods • Increased Lead Time • Excess Costs • Storage space • Caused by: • Poor parts storage • Poor Work area layouts • Working ahead of build requirements • Lack of JIT/ Pull system

  9. Waste of Transportation: Example BODY SHOP CONVEYANCE DELIVERS AMS BRACKETS TO TABLE ON THE FLOOR BODY SHOP T/M CARRIES PARTS TO RACK LINESIDE.

  10. 5. Waiting • Periods of inactivity in a downstream process that occur because an upstream activity does not deliver on time. • Results of Waiting: • Over Production • Over Processing • Idle resources • Non-Value added work • Caused by: • Line stops • Waiting for Material • Repair/Maintenance • Waiting for equipment to process • Missing tools • Non- “Full” work process

  11. Waste of Waiting: Example TEAM MEMBER WAITING ON BODY IN ST. 3900. ROBOTS IN ST. 2400 WENT DOWN CAUSING DOWNTIME

  12. 6. Over Processing • Producing more or better than the customer requires. • Results of Over Processing: • Increased Processing Time • Costs • Incorrect process/equipment • Caused by: • Refining the product in ways or areas not • important to the customer • Wait Time • Unclear Quality Standards

  13. Waste of Over Processing: Example BODY SHOP T/M SANDING DOOR THAT HAD NO DEFECTS

  14. 7. Defects/Repair/Rework • Products or aspects of the production processes that do not conform to specifications or to the customer’s expectations. • Results of Defects/Repair/Rework: • Customer Dissatisfaction • Non-Value added work • Extra costs • Extra space • Extra inspections/checks • Caused by: • Scrapped parts • Wrong or defective tools or machines • Wrong or missing processes • Poor Problem Solving • Unclear Standards

  15. Waste of Repair: Example PAINT SHOP T/M MAKING REPAIR IN SPOT REPAIR BOOTH.

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