7 wastes

Presented by:Chandra Vikas (91129)Harmanpreet (91135)Samta Satija (91155)Saurav Chopra (91169)Tarun Gupta (91172)Neeraj Sharma (91177)

THREE FORMS OF WASTE as per TOYOTA

• MURI- overburden

• MURA- inconsistency

• MUDA- elimination of waste

Types of MUDA (waste)

Overproduction

Waiting

Motion Defects

Processing Inventory

Transportation

MUDA

OVER PRODUCTION

• To produce sooner, faster or in greater quantities than the absolute customer demand (CREATED DEMAND in Toyota terms)

• Takes the focus away from what the customer really wants

• Leads to excessive inventory

WHY CONSIDERED WASTE!!!

• Costs money• Creates inventory• Space

consumption• Makes detecting

defects tough

CAUSES…

• Large batch size• Push strategy• Looks better to be

busy• Poor information

flow

RECOMMENDATIONS

•Small batch size•Producing what is ordered

WAIT/ IDLE TIME

• People or parts that wait for a work cycle to be completed

• much of a product's life is spent waiting for the next phase

WHY CONSIDERED WASTE!!!

• Poor workflow continuity

• Increased lead times

• Failed delivery • Causes bottlenecks

CAUSES…

• Unreliable supply chain

• Ineffective production planning

• Lack of multi-skilling

RECOMMENDATIONS

•Linking processes together

TRANSPORTATION

• Unnecessary movement of parts between processes

• Potential damage to products

• Wasted floor space

WHY CONSIDERED WASTE!!!

• Increases production time

• Poor communication

• Potential damage to products

CAUSES…

• Poor value stream flow

• Complex material flows

RECOMMENDATIONS

•Re-layout of work benches•Mapping product flow

INAPPROPRIATE PROCESSING

• Often termed as “using a sledgehammer to crack a nut”

• Processing beyond the standard required by the customer

• By improving processing efficiency we ultimately use less resource to achieve the same customer satisfaction

WHY CONSIDERED WASTE!!!

• Consumes resource

• Increases production time

• Works beyond specification

CAUSES…

• Attitude-’always done like this’

• Lack of standard procedures

• Outdated standards

RECOMMENDATIONS

•Low cost automation

INVENTORY

• a direct result of overproduction and waiting

• leads to increased lead times, limited floor

• space, and poor communication

• masks problems from other areas

WHY CONSIDERED WASTE!!!

• Costs money• Extra resources to

manage• Space

consumption• Makes detecting

defects tough

CAUSES…

• Large batch size• Inaccurate

forecasting• Push instead of

pull• Poor information

flow

RECOMMENDATIONS

•Small batch size•Proper communication•Forecasting techniques

MOTION

• Motion is the movement of “man”

• occurs when individuals move more than is necessary for the process to be completed

• leads to health and safety issues, which obviously lead to bigger problems

WHY CONSIDERED WASTE!!!

• Interrupts production flow

• Increased production time

• May cause injury

CAUSES…

• Poor housekeeping• Badly designed cell• No standard

operating procedure

RECOMMENDATIONS

•Jobs with excessive motion must be redesigned

DEFECTS

• A defect is a component which the customer would deem unacceptable to pass the quality standard.

• Rectification costs money with regard to time effort and materials.

WHY CONSIDERED WASTE!!!

• Adds costs• Interrupts

schedule• resource

consumption• Reduces customer

confidence

CAUSES…

• Lack of skill, training

• Machine inaccuracy

• Inefficient processing increases the defects manifold

RECOMMENDATIONS

•Employee involvement•CPI (Continuous Process Improvement)