8 Waste of Lean

What is Waste ?

Waste is any step or action in a process that is not required to complete a process ( called non value adding )successfully. When waste is removed , only the steps that are required (called value - Adding ) to deliver a satisfactory product or service to the customer remain in the process.

8 Wastes of Lean are :

a. Defects

b. Over-production

c. wasting

d. Non-Utilizing talent

e. Transportation

f. Inventory

g. Motion

h. extra processing

a. DEFECTS

Defects occur when the product is not fit for use. This typically result in either working or scrapping the product. Both results are wasteful as they add additional cost to the operation without delivering any value to the customer.

b. OVERPRODUCTION

It occurs when manufacturing product or an element of the product before it is been asked for or required . over producing a product also leads to an increase in likelihood that the product or quantities of products produced or beyond the customers requirements

c. WAITING

People waiting on material or equipment . Waiting time is often caused by unevenness in the production station and can result in excess inventory and over production

d. UNUSED TALENT

Unused talent is human potential. Waste of unused human talent . This waste occurs when organization separate the role of management from employees . When employees are given the wrong tool for the job and when the employees are not challenged to come up with the ideas to improve the work.

e. TRANSPORTAION

It includes movement of people , tool ,inventory ,equipment's or products further then necessary. Excessive movement f material can lead to product damage and defect.

f. INVENTORY

Excess inventory can be caused by over purchasing , over production work in process or producing more products then the customer needs. Excess inventory prevents detects production related problems. Since defects have time to accumulate before it is discovered.

g. MOTION

Any unnecessary movement of people equipment or machinery. This includes walking, lifting , reaching , bending , stretching and moving

h. EXTRA PROCESSING

Doing more work, adding more component or having more steps in a product or service that what is required by the customer.