ESAB CENTRAL LEAN OFFICE 7 WASTE MODULE V1.0
Over Processing
Are we applying too much ? Do we do this too often ? Is that fettling / grinding really necessary ? Are those protectors really needed ? Do we need a stud & nut – would a bolt be adequate? Is all that packaging necessary?
7 WASTE MODULE V1.0
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Waiting
This is usually the easiest waste to see
Don’t have operators waiting for machines
ESAB CENTRAL LEAN OFFICE 7 WASTE MODULE V1.0
2
Process and Method Waste
Long changeover Poor workplace design No maintenance Temporary storage Equipment problems Unsafe methods Operator motion
3
Micro waste within process
ESAB CENTRAL LEAN OFFICE 7 WASTE MODULE V1.0
Transportation
• All material movement or handling is considered non-value added by the customer. Transportation, does not add value and should be minimized or eliminated. • Causes: – Batch processing – Poor layout/distance between operations – Long changeovers – Large lots – Finite storage areas – LIFO vs. FIFO
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7 WASTE MODULE V1.0
Inventory
Turn product into CASH, reduce inventory, minimize buffers
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7 WASTE MODULE V1.0
• Why is this??
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7 WASTE MODULE V1.0
Remember ....
Total Cost Model
Raw Material Material
Housekeeping
The Good Ship?? Finished Product to Customer
7 WASTE MODULE V1.0
The Irony of Inventory
• Organisations that suffer from material & part shortages and have a poor delivery performance can usually be found to have excessive inventory levels.
7 WASTE MODULE V1.0
Waste Defined
• Activities that absorb resources but create no value • Also known as the 3Ms Muda The 7 deadly wastes Mura Unevenness of processes Muri Over burden of people or machines
Bending and reaching Double handling Excess walking Looking for stock Looking for tools Paperwork Speeds and feeds No standardised work
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Sea of Inventory
Product
Absenteeism
Delivery Transportation
Breakdown
Transportation
INVENTORY HIDES PROBLEMS
ESAB CENTRAL LEAN OFFICE 7 WASTE MODULE V1.0
Time
ESAB CENTRAL LEAN OFFICE 7 WASTE MODULE V1.0
Over processing
• Effort which adds no value to a product or service, enhancements which are ‘invisible’ to the customer. • Work which could be combined with another process. • Causes: – That’s the way we’ve always done it – Improper fixtures, tools, jigs – No standard work – Misuse of materials – Mistakes in process – Excessive checking – Closed-minded thinking – Poor layout
ESAB CENTRAL LEAN OFFICE 7 WASTE MODULE V1.0
Waste – (MUDA)
7 DEADLY WASTES
• Transport • Inventory • Motion • Waiting • Over Production • Over Processing • Defects
Excessive Inventory
• Excessive raw, WIP or finished goods inventory is wasteful • Inventory should exist for two reasons: – Buffer, required to maintain throughput in an environment where variation is present – Satisfy customer demand • Reducing variation enables inventory reduction
Waiting
• Idle time – any idle time such as watching equipment, waiting for inspection, waiting for raw material, waiting for maintenance, waiting for paper work… • Causes: – When two dependent activities are not fully synchronized – Insufficient amount of storage containers – Poor layout – Poor work balance – Unreliable equipment
7 WASTES
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7 WASTE MODULE V1.0
3 Levels of waste
1
Gross Waste
W.I.P PLANT LAYOUT REJECTS RETURNS REWORKS DAMAGED PRODUCTS CONTAINER SIZE BATCH SIZE POOR LIGHTING DIRTY EQUIPMENT MATERIAL DELIVERED TO POINT OF USE
• Causes: – Inventory is viewed as security (just in case) – Process not capable – No standard practices, lack of adherence – Poorly performing suppliers – Ineffective maintenance – Long setup times – Lack of workplace organization – Poor forecasting and production planning/scheduling – Lack of training – Producing to speculative demand (forecast) – Departmental layouts
CommunicationImຫໍສະໝຸດ alanceProblems
Manpower
Service
Motion
Take the work to the operator not the operator to the work
Eliminate walking Use pouches & dollies Everything within arms reach one at a time Parts orientation
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7 WASTE MODULE V1.0