The Seven Deadly WastesCourse Objectives Learn what the Seven Deadly Wastes

are and how they affect our business. Identify the Waste in our business and

develop an action plan to eliminate it. Develop an action plan to teach others

what the Seven Deadly Wastes are and how to eliminate them.

First – The History Lesson Have you heard of Mass Production?

This method of production was brought to the forefront with Henry Ford’s invention of the automobile.

Lean

Manufacturing Mass Production

Skilled Craftsmanship

1900’s 1930’s 1960’s TODAY

Dr. Deming Enters the Scene

Following WWII, the lean manufacturing approach was developed by American Dr. Edward Deming, to assist the Japanese economy in rebuilding from the impacts of war. The scarcity of raw materials provided the basic premise for lean manufacturing, i.e., use what is on hand in the most efficient manner.

Great Cars from Japan?

How were the first cars from Japan viewed?

How are cars from Japan viewed today?

Welcome the age of Lean Manufacturing.

The Toyota Production System In the early 1960’s TPS was

pioneered by Taiichi Ohno to reflect the philosophies of waste elimination and time management

Highly skilled “work cell” jobs Emphasis on quality and efficiency

TPS Top Three

1. The team must embrace a philosophy of having zero tolerance for waste

2. Activity on a daily basis is focused on creating a stable production environment.

3. Systems are set up to create customer “Pull” or Just-in-Time Delivery

Zero Tolerance For Waste

All unnecessary waste can be eliminated

Stated simply, the goal is perfection

Stable Production Environment

The highest quality product can only be achieved in a stable environment. Problems are instabilities that must be surfaced quickly and solved permanently

Standardization, consistency and predictability and repeatability are the goals. Improve from there!

Customer Pull/JIT Delivery A product should only be built to

meet customers demands. Build only what the customer wants, deliver it when it is expected and with perfect quality

This approach results in the best use of the company’s resources, which leads to greater profitability

Let’s get into the Waste

What are you willing to pay for? Dough, Sauce, Toppings, Toppings dropped

on the floor, Labor cost for delivery driver, Labor cost for delivery driver to stop at girlfriend’s house on the way?

What are our customer’s willing to pay for?

VALUE ADDED ACTIVITY

Value Added Activity

Value is added to a product when it changes the fundamental nature of the product.

Examples: Stamping a bracket out of a coil of

steel

All other activities are non-value added or waste

And here they are . . .

1. Overproduction2. Inventory3. Transportation4. Waiting5. Motion6. Over Processing7. Correction or

Rework

W A S T E

Overproduction

Overproduction is making more of something than the customer requested

Examples:

Running a machine for 16 hours when only 10 are required

Making 2 day’s worth of product when only 1 day’s worth is required

Inventory

Inventory waste occurs when there is more product on hand than the customer requested.

Examples:

More raw material than needed for smooth production

More work-in-process

Transportation

Transportation waste is moving the product more than is necessary

Examples:

Having three storage locations for the same material

Moving raw materials to an offsite warehouse

WaitingAnytime value cannot be added

because of a delay is defined as the waste of waiting

Examples:

Waiting for material Waiting for a machine to be fixed Unbalanced assembly sequence

MotionThe waste of motion refers to any extra

movement of the operator when they are performing the work sequence (excessive or repetitive motion also increases ergonomic issues)

Examples:

Walking 10 feet to retrieve a part or tool

Twisting around to grab a part in the back of the workstation

Overprocessing

Over processing is doing more to the product than the customer requested

Examples:

Plating a product for four hours when only two are required

Testing a product three times when the specification calls for one test

Correction/ReworkAnything that is not “done right the first time”

and requires rework inspection or touchup(Also includes scrap and appearance issues )

Examples:

Re-torquing a bolt Sorting incoming materials Checking a key dimension Trimming thread or flash from a

component

Waste in my cell!!

Waiting

• • •

Inventory

• • •

Motion

• • •

Transportation

• •

Overproduction

• • •

Over Processing

• • •

Correction

• • •

Action Plan for Eliminating Waste and Teaching Others

1. 2. 3. 4. 5. Discuss this with my coach.