7 Wastes of Lean Manufacturing | PDF Download | PPT | SLIDE
OverproductionReasons Large batches | Impossibility of quick readjustment | Proactive production | Redundant equipment, unstable quality. Consequences Premature consumption of raw materials | Procurement of materials | Excess stocks, loss of quality. How to calculate losses? The amount of unclaimed products and blanks in warehouses and intermediate operations. Within a month, a quarter, a year. How to fix? A pull-out supply chain | Equalization of the load of production lines.
TransportationReasons Irrational placement of equipment | Long distance between production sites | Inefficiently organized production flow | Remoteness of warehouses. Consequences Increased relocation costs | Additional search costs | Damage to products during transportation. How to calculate losses? The cost of moving workpieces from one operation to another, and in stock. Possible defects in case of improper transportation. Value stream map. How to fix? Optimization of equipment location | Optimization of production sites | Optimization of warehouse location.
InventoryReasons Long readjustment | Production in large batches | Imperfection of the system of production planning and supply of materials. Consequences Increase in area | Additional manpower | The need to search | The possibility of damage | The need for additional pallets. How to calculate losses? Determine how many materials are in stock that are not needed in the next week (month - depending on the supply cycle) How to fix? Pulling system of production | Equalization of production | Reduction of batch size | Improvement of the planning system.
MotionReasons Irrational organization of the workspace | Irrational arrangement of equipment and containers | Non-coordination of operations | Lack of standardized processes. Consequences Reduction of labor productivity | Fatigue of personnel | Increase in injuries and occupational diseases. How to calculate losses? Timing of worker movements, determination of time and distance. Spaghetti chart. How to fix? Optimization of the production process | Staff development | Optimization of equipment distribution | Well-organized workplaces.
Over-processingReasons Lack of standard | Lack of understanding of what the consumer wants | Imperfection of technology. Consequences Increase in the cost of manufacturing products | Increase in the time for the manufacture of products. How to calculate losses? Find out from the customer which product properties he considers necessary, and which are secondary, or not at all needed. Over-processing costs. How to fix? Standardization | Thorough study of consumer requirements.
DefectsReasons Violation of technology | Low qualification of the employee | Inappropriate tools, equipment, materials. Consequences There are additional costs: for refinement, for control; to organize a place to eliminate defects How to calculate losses? The number of defects is its cost, or the cost of alteration. How to fix? Organization of the process of ensuring the release of high-quality products | Implementation of a system of effective operation of equipment.
WaitingReasons Imbalance of production processes | Imperfection of planning | Production of products in large batches. Consequences Increasing the time for the production of a unit of production | Performance degradation | Demotivation of personnel. How to calculate losses? Timekeeping of personnel and equipment. Total downtime per shift, month, year. How to fix? Alignment of production processes | Optimization of equipment location | Reduction of readjustment time.