8 Wastes Of Lean Manufacturing

8 wastes of lean: The aim of lean is to abolish the waste from the production process. It is very important to identify the eight waste before digging it. Waste is in the least action or activity that will not enhance any cost to the product, or we can say, waste is any unwanted process that will reduce the value of the product and customer do not want to pay for that. Taiichi Ohno identified the initial seven types of waste that was called Muda in japan. Transportation, inventory, movement, waiting, over production, over processing and defects are seven types of waste identified by Taiichi Ohno. The acronym ‘TIMWOOD’ also applies to them. The eighth waste was invented by western industries in 1990s, and that was unused of workers talent or ‘Skill’ of workers was later added. Therefore,’ TIMWOODS’ is generally referred to as the 8 wastes. 1.Transport: Unwanted movement of the product during manufacturing. It is caused due to unplanned layout and product are unnecessary move from one workstation to other. In addition, excessive movement causes fatigue, wear and tear of product and equipment’s. 2. Inventory: Over production or semi-finished product to convert into finished product. Sometime customer is not receiving the order or customer is canceled the order. So, this type of products is store and called waste. The advantage of inventory is that some time vendor will offer discount on large amount of purchasing. For maintain large inventory manpower and store cost is also involved and there is chance of product damage. Over procurement, work in progress (WIP) or the production of excessive goods than the customer demands may trigger surplus inventory. Certain inventory countermeasures take in procuring raw materials only when appropriate amount needed, reducing buffers between production stages, and establishing a queue system to avoid overproduction. 3. Motion: Workers are moving from one workstation to the other workstation without necessity and the manufacturing lead time is increase. This type of unwanted motion is considered as waste. Any excessive movement of workers, vehicles, or machinery requires waste in motion. Running, raising, reaching, bending, stretching, and shifting are part of this. To improve the working conditions for workers and improve health and safety standards, repetitive motion activities should be eliminated. Some motion countermeasures consist to make sure that the tools material is place near machinery in well organized manner. 4. Waiting: These are time delay and idle times during which value is not added to the product. If the machines, men, and material wait it is waste of these resources and it demoralizes the employees. The waste of waiting includes: 1) Operator is waiting for his turn and not receive material on time. 2) Machines are idle due to line unbalance. 5. Overproduction: Excess of production over consumption. In market demand is less compare to the consumption, but industries are manufacture more to reduce the manufacturing cost. In this case inventory cost is increase and money is also block. So, it is considered as a waste. Overproduction means manufacturing additional goods via a ‘push production mechanism’. Three countermeasures to develop overproduction. Firstly, by use of ‘Takt Time’ confirms that the production rate among workstations is continue. Secondly, reducing idle time like loading and unloading, setup times. Thirdly, reduce the WIP by using a pull or ‘Kanban’ system. 6. Over-processing: Over-processing will increase machining time, material handling time and add more process steps. Due to over processing the cost of the product is increased that will pay by the customer. For reducing over processing on products, consider standard job specifications for manufacturing. Prior to starting work, always think to the customer and produce product quantity as per the requirements of the customers and try to reduce the unnecessary operations and manufactured quantities where it is required. 7. Defects: The product is not manufactured as per the specifications and tolerances given by the customer. Those products are rejected in quality inspection and consider as waste. Product/material will reject when the product/material is not suitable for use. Due to defective product/material it will loss of money and defective piece will not be reused. 8. Skills - The 8th Waste: This waste was not developed by Toyota, this 8th waste - the waste of human skills - is well known to many individuals. Also explain as no utilization of manpower skills, creativity, efforts consider in the 8th waste. This waste is developed when management not identify the skills of his workers in the organization. Employees is just following the boss order and do work as per the boss instructions. It is very difficult to optimize the process without taking help of frontline workers. This is because the worker who perform the job on shop floor is recognize the problems first and he has the solutions for that problem.

8 wastes of lean:

The aim of lean is to abolish the waste from the production process. It is very important to identify the eight waste before digging it. Waste is in the least action or activity that will not enhance any cost to the product, or we can say, waste is any unwanted process that will reduce the value of the product and customer do not want to pay for that. Taiichi Ohno identified the initial seven types of waste that was called Muda in japan. Transportation, inventory, movement, waiting, over production, over processing and defects are seven types of waste identified by Taiichi Ohno. The acronym ‘TIMWOOD’ also applies to them. The eighth waste was invented by western industries in 1990s, and that was unused of workers talent or ‘Skill’ of workers was later added. Therefore,’ TIMWOODS’ is generally referred to as the 8 wastes.


1.Transport:  Unwanted movement of the product during manufacturing. It is caused due to unplanned layout and product are unnecessary move from one workstation to other. In addition, excessive movement causes fatigue, wear and tear of product and equipment’s.

2. Inventory: Over production or semi-finished product to convert into finished product. Sometime customer is not receiving the order or customer is canceled the order. So, this type of products is store and called waste. The advantage of inventory is that some time vendor will offer discount on large amount of purchasing. For maintain large inventory manpower and store cost is also involved and there is chance of product damage. Over procurement, work in
progress (WIP) or the production of excessive goods than the customer demands may trigger surplus inventory. Certain inventory countermeasures take in procuring raw materials only when appropriate amount needed, reducing buffers between production stages, and establishing a queue system to avoid overproduction.

3. Motion: Workers are moving from one workstation to the other workstation without necessity and the manufacturing lead time is increase. This type of unwanted motion is considered as waste. Any excessive movement of workers, vehicles, or machinery requires waste in motion. Running, raising, reaching, bending, stretching, and shifting are part of this. To improve the working conditions for workers and improve health and safety standards, repetitive motion activities should be eliminated. Some motion countermeasures consist to make sure that the tools material is place near machinery in well organized manner.

4. Waiting: These are time delay and idle times during which value is not added to the product. If the machines, men, and material wait it is waste of these resources and it demoralizes the employees. The waste of waiting includes: 
                            1) Operator is waiting for his turn and not receive material on time. 
                            2) Machines are idle due to line unbalance.

5. Overproduction: Excess of production over consumption. In market demand is less compare to the consumption, but industries are manufacture more to reduce the manufacturing cost. In this case inventory cost is increase and money is also block. So, it is considered as a waste. Overproduction means manufacturing additional goods via a ‘push production mechanism’. Three countermeasures to develop overproduction. Firstly, by use of ‘Takt Time’ confirms that
the production rate among workstations is continue. Secondly, reducing idle time like loading and unloading, setup times. Thirdly, reduce the WIP by using a pull or ‘Kanban’ system.

6. Over-processing: Over-processing will increase machining time, material handling time and add more process steps. Due to over processing the cost of the product is increased that will pay by the customer. For reducing over processing on products, consider standard job specifications for manufacturing. Prior to starting work, always think to the customer and produce product quantity as per the requirements of the customers and try to reduce the unnecessary operations and manufactured quantities where it is required.

7. Defects: The product is not manufactured as per the specifications and tolerances given by the customer. Those products are rejected in quality inspection and consider as waste. Product/material will reject when the product/material is not suitable for use. Due to defective product/material it will loss of money and defective piece will not be reused.

8. Skills - The 8th Waste: This waste was not developed by Toyota, this 8th waste - the waste of human skills - is well known to many individuals. Also explain as no utilization of manpower skills, creativity, efforts consider in the 8th waste. This waste is developed when management not identify the skills of his workers in the organization. Employees is just following the boss order and do work as per the boss instructions. It is very difficult to optimize the process without taking help of frontline workers. This is because the worker who perform the job on shop floor is recognize the problems first and he has the solutions for that problem.

Tags:

Post a Comment

0 Comments