Understanding 7 Waste in Lean Manufacturing – Waste or often referred to as Muda in Japanese is an activity that absorbs or wastes resources such as expenses or additional time but does not add any value to the activity.
Today we’re going to talk about 7 Waste, so let’s dive into it.
Eliminating Waste (Muda) is a basic principle in Lean Manufacturing. The concept of eliminating waste must be taught to every member of the organization so that work effectiveness and efficiency can be improved.
7 Waste was first introduced by Taiichi Ono who works at TOYOTA Japan in the Toyota Production System.
There are 2 basic types of waste that must be considered in carrying out the waste removal analysis including the Obvious Type and the Hidden Type.
Obvious types of waste are easy to recognize and can be eliminated immediately with little or no cost.
While the type of Waste that is Hidden is Waste that can only be removed by the latest working methods, technological assistance, or new policies.
7 Waste in Lean Manufacturing
There are 7 Types of Waste Categories that are common in the Manufacturing industry, including:
1. Waste of Overproduction
Waste that occurs due to excess production both in the form of Finished Goods and WIP (Half-Finished Goods) but there is no order / message from the Customer.
Some reasons for Overproduction include long machine setup times, low quality, or the thought of “just in case” that requires it.
2. Waste of Inventory (Inventory)
Waste that occurs due to Inventory is the Accumulation of Finished Goods, WIP (Half-Finished Goods), and excessive Raw Materials at all stages of production so that it requires a place of storage, large capital, people who oversee it and documentation work (Paperwork).
3. Waste of Defects
Waste that occurs due to poor quality or the existence of damage (defect) so that repairs are needed. This will cause additional costs in the form of labor costs, components used in repairs, and other costs.
4. Waste of Transportation (Moving / Transportation)
Waste that occurs because of the layout of poor production, organization of workplaces that are not good so that it requires the activity of moving goods from one place to another. For example, the location of the warehouse is far from production.
Waste of Motion
Waste that occurs due to unnecessary Workers and Machinery Movements and does not provide added value to the product.
For example, laying a component that is far from the operator’s reach, so it requires a stepping motion from his work position to take the component.
6. Waste of Waiting
When a person or machine does not do the work, the status is called waiting. Waiting can be due to an unbalanced process so that there are workers and machines who have to wait to do their jobs, there is damage to the machine, late supply of components, loss of work tools, or waiting for certain decisions or information.
7. Waste of Overprocessing
Not every process can provide added value to the products produced or to the customer. This process that does not add value is a waste or an excessive process.
For example the inspection process repeatedly, the approval process that must go through a lot of people, the cleaning process.
All Customers want a quality product, but the most important thing is not the repeated inspection process needed but how to guarantee Product Quality at the time of manufacture. All we have to do is find the Root Cause of a problem and take action (countermeasure) that matches the root cause.
Read about what is quality control.
Seven Waste or 7 Waste is abbreviated in English to “TIMWOOD” to:
- T ransportation →Transportation
- I nventory →Inventory for productions
- M otion →Movement
- W aiting →Waiting
- O verprocessing → Excessive process
- O verproduction → Excessive on productions
- D efect →Defects of products