waste of

1
Exordium
waste of overproduction
7 Types of Waste
Waste of transportation
Waste of making defective products
Waste of movement
Waste of inventory
Waste of waiting
Waste of processing itself
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2
Exordium
Motions of Worker
Waste Non Value-Added Work
Profit
Value- Added Work
Profit
Waste
Waste
Non Value-Added Work
Value- Added Work
Non Value-Added Work
Customer pays money only for Value-added Work
Increase Value-added Work
3
Exordium
Importance of Cost Reductions
How to earn more profit?
Selling Price
120
100
Profit
80
Depend on How to produce
60
Manuf. Cost
40
20
Increase the selling price
Cost Profit
Reduce the cost
4
1. JIT
Just in Time
Initial conditions
Leveled Production (Heijunka) (volume types)
Takt time
Basic principles
Pull Production System
Just in Time
Establish a production flow
? Reduce production cost ? Decrease the
lead-time of productions.
5
1. JIT
1-1. Takt Time
Required time to produce one unit
All the processes need to work at the same pace
to ensure a consistent production flow.
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Set the
480 mins./day
Daily Operating Time
3.2 mins./pc.
Takt Time

Daily Production quantity
150 pc./month
TAKT is a German word meaning Meter
Daily Production quantity
Monthly Operating Time
Total Monthly Production
6
1. JIT
Single-piece flow Production system
Reduce inventory between processes (WIP) Reduce
lead-time. Easy to keep continuous improvement.
7
1. JIT
1-3. Pull Production System
The units manufactured by an upstream process are
automatically transferred to the down process.
?tends to accumulate W.I.P.
Push production method
Pull production method
The earlier process produces only the amount of
parts used by the later process. ?reduce
inventory level at every process.
Produce only the quantity required by Next Process
OEM
Following Process
Previous Process
Information
Information
KANBAN
KANBAN
KANBAN
Complete Elimination of Waste
8
3. Lead-Time
LEAD TIME
Lead Time time required to process from start
to end
(i.e. from raw material processing till packing
goods)
Lead Time Processing Time Non Processing
Time


Minimize Lead Time
Minimize Non Processing Time
Many types of MUDA will be highlighted when we
minimize the Non Processing Time
9
4. Visual management
Production Management Board
Display board of planed quantity vs actual
production
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96
94
-2
143
138
-5
191
186
-5
Check on hourly basis, take appropriate action
against each abnormality
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Visual management ?Find problems at once
Everybody can know current situation
10
6. Standard Work
Standard Work
Everything must be standardized including the
work sequence, the minimum inventory of parts on
hand and the location of machinery
Every operator should follow the work sequence
the same way every time.
By standardizing work,
Reduce defects (Improve quality) Increase
efficiency Reduce inventory Reduce setup times
11
7. 7 Types of Waste
Waste of over-production
Over-production is the most deadly of wastes
Increase non-value added work Unnecessary
transportation Increase inventory cost (space,
worker)
Counter measures
1.One-piece flow 2.Leveling 3.Changing setup
quickly and often 4.Reduce reworks (defect parts)
12
7. 7 Types of Waste
Real efficiency and pretended efficiency
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pretended efficiency
100 pieces by 10 worker per day 120 pieces by 10
worker per day
Required quantity 100 pieces per day
Over production
Real efficiency
100 pieces by 10 worker per day 100 pieces by 8
worker per day
Real efficiency ?No over production
13
7. 7 Types of Waste
Waste of waiting
Waste of time in waiting
Counter measures
Line balancing One operator handles several
machines at once (Multi skilled
worker) Leveling
14
7. 7 Types of Waste
Line balancing
Before
After
11
21
No. of Workers (include other improvement
effects)
54
88
Line Balancing Efficiency
15
7. 7 Types of Waste
Waste of transportation
Transportation does not add any value to the
product

• The losses due to transportation are
• Increase moving cost
• Increase risk of damage
• Space machine

16
7. 7 Types of Waste
Waste of making defects
Defects interrupt the smooth flow of production
Making defective products is very expensive for
manufacturing
If you cant prevent a defects making process,
you must stop the process. Never send defective
products to the next process.
17
8. Find wastes
2) Process Flow Analysis Chart 3) Time Study
18
8. Find wastes
4) Work Content Analysis
Find out non-added value work Analysis of
combined process
19
Methodology for Improvement Activity
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1. Not just Improvement But Need based
improvement 2. Improvement by involving employees
at all level 3.Sustainable Improvements by asking
5 times Why 4. Once decided then implemented the
Improvement Idea without any delay 5. Before
Kaizen Activity Quality and Safety must be
checked 6. Initially Small initiatives should
target on process improvement
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