Eight manufacturing
wastes
In Japanese management system there are seven
manufacturing wastes. Some extend this into eight manufacturing
wastes. I also prefer to use this. When it comes to lean manufacturing
anything does not add value to the final product is treated as
wastes. Therefore we can understand these eight wastes as anything
that are not used in value adding process.
Below I have listed these eight wastes with explanations
1. Overproduction
Lean manufacturing depends on manufacturing everything when they
are just required. Overproduction refers to the products produced
before they are actually required. One of the important concepts
of lean manufacturing is the pull scheduling. This means the production
is pulled by the process above them. This concept is a contrast
to traditional manufacturing which relies on pull scheduling.
In this case production will be carried out with the full capacity
of the facility.
2. Waiting
Waiting in lean manufacturing context means waiting for processing.
This is a problem associated with batch processing. In batch processing
usually the time in waiting is very high in comparison to just
in time manufacturing processing. Every item in the batch has
to wait until everything is taken for the processing at once.
But in lean manufacturing it will only take the time required
to manufacture the particular part. So it has no waiting.
3. Higher Transportation
Transportation does not add any value to the product. Actually
it takes more resources. Transportation adds up to the lead-time.
It also uses space and money. Create delays.
4. Inappropriate Tooling
Correct tooling for the job is necessary to carryout the job.
Correct tools are not the tools which are expensive or complex.
They are the best tools for the particular purpose. Using inappropriate
tools in the manufacturing process is a waste because it will
take more resources and also it may not deliver the result expected.
5. Higher WIP
Work in progress is a direct result of over production and waiting.
While WIP is a reflector of imperfections the system has, it also
a waste itself. WIP is money stuck in the manufacturing facility.
It hides the quality defects and other problems in the system.
6. Ergonomic imperfections
High amount of motion in work is a waste because it makes manufacturing
process inefficient. Excess motions also affect health of the
workers. This is a long term cost for the organization. Good ergonomics
in work is a trait of lean working place.
7. Defects
No need to explain it more. Defects are wastes obviously. Defects
are due to the various problems in the system. Actually this might
be the final outcome of the wastes above. Defects are money which
will end in the waste bins.
8. Underutilization Of Human Talents
This is the last or the eighth waste. For me
this is the most important among all the wastes listed above.
By using human resources effectively every waste above can be
eliminated from the system. Every organization has a huge potential
for improvement in this area. This is because every organization
on the planet use only a fraction of potential of their employees.
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