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    9 Wastes

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    katipearachchiuk
    The document discusses the nine types of waste identified in lean manufacturing, known as the "9 wastes". It was Taiichi Ohno who originally identified 7 types of waste in manufacturing organizations. Two more categories - talent and energy - have since been added. The 9 wastes are overproduction, transportation, inventory, talent, motion, defects, processing, waiting, and energy. Examples of tools and techniques for addressing each type of waste are provided. The elimination of waste, not just the reduction, is seen as vital for increasing organizational competitiveness.

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    9 Wastes

    Uploaded by

    katipearachchiuk
    2K views3 pages
    The document discusses the nine types of waste identified in lean manufacturing, known as the "9 wastes". It was Taiichi Ohno who originally identified 7 types of waste in manufacturing organizations. Two more categories - talent and energy - have since been added. The 9 wastes are overproduction, transportation, inventory, talent, motion, defects, processing, waiting, and energy. Examples of tools and techniques for addressing each type of waste are provided. The elimination of waste, not just the reduction, is seen as vital for increasing organizational competitiveness.

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    The document discusses the nine types of waste identified in lean manufacturing, known as the "9 wastes". It was Taiichi Ohno who originally identified 7 types of waste in manufacturing organizations. Two more categories - talent and energy - have since been added. The 9 wastes are overproduction, transportation, inventory, talent, motion, defects, processing, waiting, and energy. Examples of tools and techniques for addressing each type of waste are provided. The elimination of waste, not just the reduction, is seen as vital for increasing organizational competitiveness.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    2K views3 pages

    9 Wastes

    Uploaded by

    katipearachchiuk
    The document discusses the nine types of waste identified in lean manufacturing, known as the "9 wastes". It was Taiichi Ohno who originally identified 7 types of waste in manufacturing organizations. Two more categories - talent and energy - have since been added. The 9 wastes are overproduction, transportation, inventory, talent, motion, defects, processing, waiting, and energy. Examples of tools and techniques for addressing each type of waste are provided. The elimination of waste, not just the reduction, is seen as vital for increasing organizational competitiveness.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 3

    AnInfoGuide. The9Wastes.

    ThetermLeanmanufacturingwaspopularisedbyWomackandJonesintheirbookTheMachine thatchangedtheworld.Thisbookbenchmarkedmanufacturingcompaniesaroundtheworldand found,atthattime,thatJapanesemanufacturingcompaniesweretypicallymuchmoreproductive andefficientthantheirWesterncounterparts. AfewyearsbeforetheThemachinethatchangedtheworldcameoutTaiichiOhnohadpublished abookcalledToyotaProductionSysteminitheexplainedthemainfoundationsoflean manufacturing.TheseprinciplesguidedtheJapanesecompaniesthatwerefoundtobeworldclass byWomackandJones.TaiichiOhnodevised7categorieswhichcovervirtuallyallofthemeansby whichmanufacturingorganisationswasteorlosemoney;thesehavebecomeknownasThe7 wastes.2morehavebeenaddedtotheclassictomakeour9wastes. Wasteistheuseofresourcesoverandabovewhatisactuallyrequiredtoproducetheproductas definedbythecustomer.Ifthecustomerdoesnotneeditorwillnotpayforitthenitiswaste,this includesmaterial,machinesandlabour.TheJapanesewordforwasteismudaandisoftenusedin books,trainingcoursesandbyleanconsultantstomeanwaste. The9wastesare: 1. Overproductionandearlyproductionproducingovercustomerorders,producingunordered materials/goods. 2. MaterialTransportationhandlingmorethanonce,delaysinmovingmaterials,unnecessary movingorhandling. 3. Inventoryunnecessaryrawmaterialsinstores,workinprocess(WIP),&finishedstocks. 4. Talentnotusingalltheskillsofyouremployees 5. PeopleMotionmovementofequipmentorpeoplethataddnovaluetotheproduct. 6. ReworkorDefects.Producingorreworkingscrap. 7. Inappropriateprocessesunnecessaryprocessingorprocedures(workcarriedoutonthe productwhichaddsnovalue). 8. Delays.Waitinghangingaround,idletime(timewhennovalueisaddedtotheproduct). 9. Energy. Othershaveincludedadditionalcategorieswhichinclude; TalentandenergyaretheadditionstoOhnosoriginal7. Whilethe9wastesisnotatoolinitselftotackletheproblemswithinacompanywhichare causingthewasteinfirstplace,theydoplayavaluableroleintacklinginefficiencyandtherefore cost. Theideaof9wastesisusefulbecauseitallowsacompanytocategoriseproblemsandthenfocus attentionintheappropriateareasoncetheyhavebeenidentified.Therearemanytoolsand techniquesintheleantoolboxwhichcanbeappliedtomanyareasofproductioninordertotackle anyoneofthesewastes.Afewexamplesarelaidoutbelow.

    AnInfoGuide. The9Wastes.
    1. Overproduction Oftencausedbyqualityproblems,acompanyknowthatitwillloseanumberofunitsalongthe productionprocesssoproducesextratomakesurethatthecustomerorderissatisfied.Thesekind ofissuecanbetackledusingmistakeproofingmethods(Pokayoke)andbyunderstandingthe machineprocesscapabilitiesoftheproductionequipment.Statisticalprocesscontrol(SPC)willalso helpmonitorproductionoutputsandgivewarningofproblemsbeforetheyoccur. Ifthereasonacompanyisoverproducingisbecauseofsmallordersandeconomicbatchsizesthen SetupreductiontechniquessuchasSMEDcanhelp.Ifacompanycanreduceitschangeovertime thenitisthenabletoproducesmallerbatcheseconomically. Overproductionhasbeensaidbysometobetheworstofthe7wastesasitencompassestherestof thewastes,oftenthemaindrivingforceforJIT(Justintime)systems. 2. MaterialTransportation Factorylayoutscanoftenbethefundamentalcauseofexcesstransportation.Whenappropriate,re layingoutthemachineswithinafactoryfromafunctionaltoacellularlayouthasbeenfoundby manycompaniestohelpnotjustreducetransportationwastebutalsoreduceWIPandwaiting. Excessinventorylevelscanalsoleadtowastedhandling. 3. Inventory Manycompaniesorderoverandabovewhatisrequiredtofulfiltheorder,thismaybeduetoquality problemsalongtheproductionprocessortheoftenmistakenbeliefthatissavesmoneybyordering largerquantities.Thetruecostofexcessinventorylevelsshouldbecarefullyanalysedbefore orderingexcessrawmaterialssimplybecausethepurchasepriceisless. Tacklingtherootcauseofthequalityproblemsshouldalsobeapriority. 4. Talent Thepeopleintheprocessworkwiththedaytodayfrustrationsandissues.Understandingand resolvingthesefrustrationscanhavesignificant&easyresults.Involveallyouroperatorsinthe solutionsandtheresultsandbeimpressive. 5. PeopleMovement SimpleGoodHousekeepingisaveryeffectivewayofreducingwastedmovementbymenand materials.5Sisatechniqueusedbymanycompaniestofocuseffortonkeepingtheworkplacetidy withunusedmaterialsandmachinesdisposedoffsoasnottocreateunnecessaryclutterand thereforesearching.Relayingoutthefactorycanalsohelpreducemotionwaste.

    AnInfoGuide. The9Wastes.
    6. Rework&Defectiveunits IfyoudontdoitalreadyrecordandanalyseeverythingthatsNotRightFirstTime,foratleasta month.AsimpleParetowillhelpyouprioritiesyourefforts. 7. InappropriateProcesses Reworkisatypicalexampleofoverprocessingasdiscussedearlierreducingtherootcauseofthe qualityproblemissolutioneliminatingrework.Techniquessuchas5whys,SPCandmistakeproofing (Pokayoke)areavailabletohelpidentifyandeliminatecausesofqualitydefects. 8. Delays&Waiting Productswaitingaroundinfactorieseitherasfinishedgoodsorworkinprogress(WIP)another majorcauseofwaste.WIPiscommonlycausedbyproducinglargebatchsizeswhereagainSMED techniquescanhelp.Delaysarealsoprevalentininformationsystems,productionofschedules& clarityofthenextpriority. ConcentratingonkeepingbottleneckprocessesgoingarealsoagoodwayofreducingWIP,thebook TheGoalbyEliyahuM.Goldratthasalottosayonthisandhasbeenfoundtobeveryusefulby manymanufacturingmanagers. 9. Energy Pooruseofalltypesofenergyisawaste&canbeexpensive.Compressedairorwaterleaksoften getignoresbutareexpensive.Howlongisyourequipmentswitchedonfor? Overview Ifyouweretorecordallofthenonvalueaddedactivitiescarriedoutinatypicalmanufacturing companydonotbesurprisedtofindoutthat99%ofallyouractivitiescarriedoutarenonvalue adding,eventhebestmanufacturersmanage95%.Theeliminationofwastenotjustreducingitisa vitalcomponentofincreasingcompetitivenessofyourorganisation. TheManufacturingAdvisoryServiceisavailabletohelpsmallandmediumsizedmanufacturing tacklealltheissuescausingwaste.Ifyouwouldlikehelp,adviceorinformationaboutanyofthe9 wastesorothertechniquesraisedinthisarticlethenpleasegetintouchwithourHelpdeskon(0845) 6083838.

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