8 Types Of Wastes In Lean Manufacturing

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8 types of Wastes in Lean manufacturing are to be discussed here.

8 TYPES OF WASTES IN LEAN MANUFACTURING :

  • Waste means any activity that adds no value for the customer.
  • The origin of lean manufacturing comes in picture so as to eliminate these non value added work (WASTE).
  • This becomes most important for an organization to reduce waste without harming productivity and to do value added acts every time.
  • There are mainly eight types of wastes in lean manufacturing which we need to remove from the system for increased production, on time production  and quality production, with reduced associated costs.
  • To reduce or remove the eight forms of wastes, we have to know which are the eight types (forms) of wastes.
  • To keep in mind the 8 types of wastes in lean manufacturing please go through the DOWNTIME image below.

Wastes in lean manufacturing

These eight forms of wastes are as follows-

1. Defects - 

  • The worst form of waste.
  • Production of NC (Non Conforming) parts.
  • Production of NC  assemblies.
  • Increased reworks and scrap.
  • Reduced process efficiency.
  • Wastes machine, process and assembly time.
  • Non - value added tool wear. 
  • Increased Waiting time.


2. Overproduction -

  • Improper amount of production.
  • Production at improper time span.
  • Produce the proper amount at the proper time and avoid overproduction.


3. Waiting - 

  • Waiting on parts.
  • Waiting for supplies.
  • Waiting for information.
  • Time and resources are wasted due to waiting.


4. Non utilized talent or Untapped Employee Potential - 

  • Employees are the best assets of any organization.
  • Creation of an atmosphere where ideas are encouraged. 
  • Creation of a culture where employee's ideas are heard & evaluated.
  • Implementation of the ideas of the employee.
  • Recognize and reward the employees for the best ideas.


5. Transportation - 

  • Excessive travel.
  • Excessive movement of materials.
  • Improper process layout.
  • Improper planning.

*Eliminate excess transportation due to improper planning and process layout.  

* Value Stream Mapping helps to visualize material movement.


6. Inventory in excess/Excessive inventory - 

  • Direct result of overproduction.
  • Poor purchasing practices.
  • Over purchasing.

These things leads to excessive inventory.


7. Motion - 

  • Any non value added movement performed by the operator.
  • Unorganized workstation and supplies. 
  • Organize the workstation and supplies.
  • Examine the motions required to perform the task by the operator.


8.  Extra or Non Value Added Process - 

  • Performing needless operations.
  • Performing inefficient processes.
  • Using wrong tools for the job.

* Use right process and the correct tools to reduce process-waste.

#
Location: India

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