7 Waste of Lean Manufacturing

7 Waste of Lean Manufacturing

In lean manufacturing there are 7 types of waste is identified because of these waste inefficiency/looses occur during production.These types of waste  is associated with one of the 3M Elements-Muda. Muda is a Japanese word his english meaning is uselessness,wastefulness. Muda is any activity which does not add any any value for customer.Some people translate muda is a non value adding work in our production system.

These waste include any things beyond necessary to deliver a required quality product to customer as quickly as possible,For example if any item assembly required 4 screw in that case we add one more screw that is 5th screw in assembly this would be the waste.2nd example if in our workplace there is unnecessary machine part,items are there if we remove the same from workplace by this we reduced wastage of floor space area.These simple practices improve production efficiency and resolve the issue or waste caused by the 7 waste.

5S System is the most important lean manufacturing tools which helps us to control these 7 types of waste.

7 Types of Lean Manufacturing Waste:-

• Over Production
• Defect in the End Product
• Over Processing
• Transportation
• Excess Material Inventory
• Excess Movement
• Waiting

1.Over Production

   

      Produced material more than demand because of this lot of losses/waste is there like extra manpower hours,material wastage in advance,energy and oil wastage etc

2.Defect in End Product

    Because of this waste type our process cost,manpower cost increase by reworking these end product defect.

3.Over Processing

     By over processing our inventory cost increase, rejection increase during handling.For example if our last assembly station requirement per hours is 10 part and we produced 12 part these 2 extra part per hours is our wastage in form of inventory cost,floor space wastage,rejection during handling etc.

4.Transportation

    Extra movement of material from one warehouse to other warehouse.

5.Excess Material Inventory

    This waste produced by unprocessed material stock for care taking this unprocessed stock number of waste are included like waste of capital ,waste of storage area,lighting of the storage area,transportation etc.

6.Excess Movement

     This waste is mainly because of improper production line balancing this increase movement of product from one station to other station and manpower movement as well for controlling this waste always use produced one pack one or single piece follow process.

7.Waiting

    This waste is also because of improper line balancing.