LEAN Continuous Improvement What is Waste? Traditional Lean identifies 7 key areas of waste. Processes either add value or waste to the production of a good or service. To eliminate waste, it is important to understand exactly what waste is and where it exists. 7 Wastes Description Countermeasure Making something before it is actually Schedule and produce only what is needed. immediately needed – pace rate of Overproduction causes - production to the rate of customer Excess inventory demand. Degraded quality and productivity Use a pull system to control how Excessive lead times much is produced. High storage costs Pull system: production or service Overproduction Difficulty in detecting errors process designed to deliver goods or services as they are required by Examples: the customer, also called “build to Printing hard copy forms order” or “just in time”. Only Purchasing “just in case” produce what is needed to reduce Processing too soon inventory. Preparing reports that are Reduce set-up times so that unused/unread smaller batches can be produced. Time when work-in-progress is waiting for Link processes together so that one the next step. Much of a product/process feeds directly into the next. This lead time is tied up in waiting for the next can dramatically reduce waiting. operation. Use standardized work instructions to ensure that consistent methods Examples: Waiting are used. System/response downtime Approvals from others Awaiting customer information Late start meetings Late reports, paychecks, projects Unnecessary movement of materials, Mapping flows, design a linear, or people. Transporting sequential flow end to end. between processes adds no value to the end Ensure works in progress are product. meeting just in time customer Transport/ need. Motion Examples: Avoid continual changes of job Too many layers for electronic files priorities. Copy machine located far from user Reaching for commonly used supplies
LEAN Continuous Improvement What is Waste? Traditional Lean identifies 7 key areas of waste. Processes either add value or waste to the production of a good or service. To eliminate waste, it is important to understand exactly what waste is and where it exists. 7 Wastes Description Countermeasure Overproduction Making something before it is actually needed. Overproduction causes - Excess inventory Degraded quality and productivity Excessive lead times High storage costs Difficulty in detecting errors Examples: Printing hard copy forms Purchasing “just in case” Processing too soon Preparing reports that are unused/unread Schedule and produce only what is immediately needed – pace rate of production to the rate of customer demand. Use a pull system to control how much is produced. Pull system: production or service process designed to deliver goods or services as they are required by the customer, also called “build to order” or “just in time”. Only produce what is needed to reduce inventory. Reduce set-up times so that smaller batches can be produced. Waiting Time when work-in-progress is waiting for the next step. Much of a product/process lead time is tied up in waiting for the next operation. Examples: System/response downtime Approvals from others Awaiting customer information Late start meetings Late reports, paychecks, projects Link processes together so that one feeds directly into the next. This can dramatically reduce waiting. Use standardized work instructions to ensure that consistent methods are used. Transport/ Motion Unnecessary movement of materials, or people. Transporting between processes adds no value to the end product. Examples: Too many layers for electronic files Copy machine located far from user Reaching for commonly used supplies Mapping flows, design a linear, sequential flow end to end. Ensure works in progress are meeting just in time customer need. Avoid continual changes of job priorities.
What%20is%20waste_FINAL.docx