WK104 Seven Waste

1、03F 7Waste.ppt.ppt7 Wastes2Seven WastesNOS House Foundations3Seven Wastesq Understand Waste Definitionq Understand the Seven forms of Wasteq Identify examples of eachq Understand steps to eliminate wasteModule Objectives4Seven WastesPizza Dough ?Sauce ?Toppings ?Box?Toppings dropped on floor ?Energy

2、 for ovens ?Energy for ovens left open? Ovens left on overnight ?Phone ?Idle Workers?What are you paying for?5Seven WastesNOS Focuses on the CustomerThe Customer is the ONLY one who defines the VALUE of the product.Customers support suppliers who best meet their needs with additional businessAnythin

3、g not adding Value to the product is WASTE.Ask yourself: Would the Customer pay for this?6Seven WastesWasteWaste is: - anything that takes time, resources or space but does not add value to the product or service delivered to the customer.7Seven WastesToyotas Famous Pursuit of WasteMuda- (Waste) The

4、 seven forms of Waste, and the focus of this module Muri- (Overburden) Overworking or stressing of an operator or machine Mura- (Unevenness) The imbalance of workload amongst workers8Seven WastesThree Types of ActivitiesValue Add Any activity that changes the shape, form, or function of material to

5、meet customer requirementsNon Value AddActivities that add cost but not value to the product (WASTE), as defined by the customer.Incidental / NecessaryWork that needs to be done but does not add direct value to the part9Seven WastesKEEPValue AddREDUCEIncidentalELIMINATENon Value AddDoes Not ExistVal

6、ue AddNecessaryNon Value AddNecessaryUnnecessaryUnnecessaryValue Add Matrix10Seven WastesCustomers are Demanding Shorter Lead TimesCustomer OrderCustomer OrderProduct ShipmentTimeLean helps to shorten the timeline between the customer order and the product shipment.Performance that was OK in the pas

7、t is not OK today. How do we deal with these demands? By eliminating waste!Product ShipmentWASTEWasteTime11Seven WastesTransportationMovement between process steps that does not add valueWaitingIdle time created when material, information, people are not readyOver-processingEffort that creates no ad

8、ditional value from the customers perspectiveDefectsWork creating errors or lacking something necessary for completionInventoryMore information, material, or projects on hand than the customer needs right nowMovement or Motion Physical movement not adding valueExtra /Over-ProductionGenerating more o

9、utput than the customer needs right now7 Forms of WasteWhich wastes to you see in your own factories?12Seven WastesHow to Remember the 7 WastesTransportationWaitingOver-processingDefectsInventoryMovement or MotionExtra-production (or Over-production)13Seven WastesTransportationMovement between proce

10、ss steps that does not add valueWaitingIdle time created when material, information, people are not readyOverproductionGenerating more output than the customer needs right nowDefectsAny process, product, or service that fails to meet customer specificationsInventoryMore information or material on ha

11、nd than the customer needs right nowMovementPhysical movement not adding valueExcess / Over-processingEffort that creates no additional value from the customers perspectiveDefinitions, Effects, Causes, Examples14Seven WastesTransportation Definition: Movement of product or materials from one place t

12、o another (by hand carry, by cart, by conveyor, by truck, etc.) without adding value. Effects: The more you move material, the more opportunity you have for damage or injury. Transportation also adds cost, requires more space and disconnects parts of the value stream Causes: Poor factory layout, or

13、poor cell design Examples: .?15Seven Wastes Previous situation at VJ (2003): Cutting was centralized in one building, with components stored in a warehouse, away from the place of use. Result:Additional personnel needed to track materialAdditional storage location other than point of useAdditional m

14、aterial handlers and equipmentComponent WarehouseTransportation Waste Example16Seven WastesWaitingDefinition: people or machinery“sleeping”or sitting idle due to material shortages, unbalance work loads, missing instructions.Effects: idle time, lost capacity, angry customersCauses: unclear or no sta

15、ndard, layouts, poor training, workload imbalance of operator, long changeovers, big batch productionExamples .?17Seven WastesIn the above photo, why was this waste generated?Waste of Waiting (People)18Seven WastesWaste of waiting (machine)Why was this waste generated?Deep well pressing machine19Sev

16、en WastesOver ProductionDefinition Creating more than, or ahead of, customer requirement. Effects: poor use of time, excess transportation, extra space, inventory carrying costs, potential quality issues. Overproduction leads to all other forms of waste.Causes (examples): unstable work environment (

17、downtime, quality issues, color issues, inspections, testing, “Just in case inventory, etcExamples .?20Seven WastesWaste of OverproductionWhy is it generated?21Seven WastesFinished Goods Warehouse In 5,500prsOut 1,500prsMore parts = More moneyBut the Result is Overproduction extra machining extra de

18、fects extra handling extra space extra paperwork extra people extra overhead“more inventory is better.” Less inventory is risky.Traditional Management Philosophy22Seven WastesDefects (Correction, rejects)Definition: Producing a product that must be touched up, reworked, or scrapped -any Rework or Re

19、jectEffects: loss of productive time, duplicated effort, material costs, potential defect to customerCauses (examples): unclear or no standard, incorrect machine settings, poor in station quality, poor training, poor or no error-proofing,etc.Examples .?23Seven WastesBondGapPaintTouch-upDefect Exampl

20、es24Seven WastesInventoryDefinition Excess material (raw, WIP, finished) beyond what is necessary to meet demandEffects: lengthens lead time, ties up working capital, increases risk of obsolescence, spoilable, and quality issues. Inventory also hides problemsCauses: unclear or no standard, Incorrect

21、 machine settings, fear of running out (Just In Case), etc.Examples.?25Seven WastesIn process InventoryComponent W/HWaste of Inventory26Seven WastesInventory Hides ProblemsRaw MaterialFinished GoodsPoorSchedulingMachineBreakdownQualityProblemsLongTransportationSupplier DeliveryLineImbalanceLong Set-

22、Up TimeAbsenteeismCommunicationProblemsLack ofHouse-KeepingLots of inventory = smooth sailing because inventory HIDES problems27Seven WastesSea of InventoryReducing inventory exposes hidden problemsPROBLEMS ARE GOOD!Raw MaterialFinished GoodsPoorSchedulingMachineBreakdownQualityProblemsLongTransport

23、ationSupplierDeliveryLineImbalanceLong Set-Up TimeAbsenteeismCommunicationProblemsLack ofHouse-Keeping28Seven WastesSea of InventoryRaw MaterialFinished GoodsPoorSchedulingQualityProblemsLongTransportationVendorDeliveryLong Set-Up TimeAbsenteeismProblem Solving can then permit smooth sailing once again, but withLESS INVENTORY!29Seven WastesMotionDefinition Ergonomic stress or extra movement by people not required to add value. Effects: wasted or lost time, ergonomic problems, injuries, and costCauses: cell layout, machine set-up, poor designsExamples: Walking, bending, lifting, tw