How we can avoid the seven waste in manufacturing?

Eliminating the seven wastes is something that can be done through the implementation of Lean and the various lean tools, however the focus of your implementation should not be to identify and remove waste. Instead you should use the principles of lean manufacturing to identify value according to the customer and make those value adding processes flow through your organization at the pull of the customer. This approach helps you to make your value adding processes more efficient and causes the waste to literally “dissolve.”

1. Transportation-This is unnecessary motion or movement of materials,such as work in process being transported from one operation to another

Caused by-a) Badly designed process/cell b) Poor value stream flow c) complex material flow

2. Inventory-Any raw material work in process or finished goods which are not having value added to them.This refer to inventory that is not directly to fulfill current customer order.Inventory includes raw materials , work in process and finished goods

Caused by-a)Inaccurate forecasting b) Excessive downtime/set up c) Large batching

3. Motion-Motion is the movement of people.Waste of motion occurs when individuals move more than is necessary for the process to be completed.To move and add value is called work.To move and not add value is called motion, then means moving without working, moving and adding cost

Caused by-a)No standard operating procedure b) Badly designed work cell c) Inadequate training

4. Waiting-Also known as queuing waiting refer to the periods of inactivity in a downstream process that occur because an upstream activity does not deliver on time.

Caused by- a) Shortage & unreliable supply chain b) Downtime/breakdown c) Ineffective production planning d) Quality,design,engineering issue.

5. Over production-To produce sooner,faster or in greater quantities than the absolute customer demand . Overproduction discourages a smooth flow of goods or services and leads to excessive inventory .Manufacturing just in case

Caused by- a)Large batch size b) Poor people utilization c) Lack of customer focus

6. Over Processing-Processing beyond the standard required by the customer.By improving processing efficiency we ultimately use less resource to achieve the same customer satisfaction.

Caused by-a) Out of date standards b) Not understanding the process c) Lack of innovation and improvement d)  Lack of standard operation procedures

7. Defect/Rework-Non right first time.A defect is a component which the customer would deem unacceptable to pass the quality standard.

Caused by- a) Out of control/Incapable processes  b)  Lack of skill,training and on the job support c) Inaccurate design and engineering d) Machine inaccuracy.

8. Knowledge disconnection-Occurs when there are disconnects within the company/departments and between its customers and suppliers

Caused by-a) Lack of customer focus b) Complex hierarchy c)  Improper planning

All causes need to be eleminate