CIJ is Sponsored By:

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Sponsored by:

About MEMohammed K. Barakat

• Industrial Engineer, The University of Jordan

• Business Excellence Manager-FINE Hygienic Paper Company

• Professional Engineer in Industrial Engineering (PE), (JCPQA-JEA)

• Project Management Professional (PMP), (PMI)

• Risk Management Professional (PMI-RMP), (PMI)

• Certified Six Sigma Black Belt (CSSBB), (ASQ)

• Certified Six Sigma Green Belt (CSSGB), (ASQ)

• Microsoft Certified Technology Specialist (MCTS), (Microsoft)

• Microsoft Certified Trainer (MCT), (Microsoft)

mohammedbarakat

MohdBarakat

MohdKBarakat

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What is Waste?

Waste or muda is anything that

does not add value to the product

or service.

Waste is something the

customer will not pay for.

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Waste Elimination

Study the

process

Recognize the

wastes

Measure the

waste

Identify the root

cause

Eliminate or reduce

the root cause

Sustain the

improvement

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Cause & Effect

Man/Woman

Method

Machine

Material

Measurement

Mother Nature

Mindset

Defect

Overproduction

Waiting

Neglected Resources

Transportation

Inventory

Motion

Extra Processing

The 7 M’s The 8 Wastes

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The 7 M’s

Men/Women

Manual and mental skills used by a person to execute

an assignment

Example: lack of training

Methods

The sequences and steps necessary to convert

material or information into a product or service.

Poorly designed procedures or lack of standard work

with inconsistent application create waste.

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The 7 M’s

Machines

Mechanical, electrical or electronically operated

devices used to perform a task

using the wrong machine for the wrong task.

Poorly designed tools

Material

Physical matter or information converted or acted on

to create another form with added value.

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The 7 M’s

Measurements

An action using a physical device to record a characteristic

and compare it to a standard or expected outcome.

Used only if the waste cause is the instrument itself. If the person taking the

measurement causes the error, categorize it as either Men/Women or Methods.

Mother Nature

The environment and immediate surroundings of the task or process

weather, humidity, moisture, temperature, wind, noise, dust,

odors, lighting, ground, and vibration

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The 7 M’s

Mindset

The fixed mental attitude about a situation, event or belief.

May be derived from culture, value system, experience, or

management directives.

Characterized by inflexibility and does not allow

for change or new ideas.

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DOWNTIME

Defects

A product or information that does not meet customer expectations.

Damaged, improperly functioning product, missing or inaccurate

paper work, poor quality, late deliveries, or rework.

Overproduction

Converting material or information before it is needed by end user or downstream customer.

It applies to WIP and finished goods.

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DOWNTIME

Waiting

Person or machine idle due to lack of information or material required to continue operation.

Neglected Resources

Omitting, neglecting, ignoring or misusing the best resources available for the application at

the time.

Not using the best talent, equipment, machines, or software.

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DOWNTIME

Transportation

Unnecessary movement of product or information that does not add value to meet the customer’s

requirements.

Inventory

Material or initial information in a process queue.

Raw material and Finished Goods

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DOWNTIME

Motion

Unnecessary movement by people that does not add value to meet customer’s requirements.

reaching, bending, walking or any other unnecessary movement.

Extra Processing

Producing and providing more features, information or work than what is required to meet

customer’s requirements. It includes extra steps done to meet customer requirements.

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DOWNTIME

(Defects)

Mindset Organization culture ,

management

We've always done that !Men/Women

Lack of job training

Poor employee skills

Lack of job rotation

Methods

Poor SOPs

Ask operators what improves processes

Machines

Lack of scheduled

preventive maintenance

Wearing out tools /machines

Materials

Defected material used

Cheap /inferior material used

Material nonconforming to

SpecsMeasurement

Improper calibration

Incorrect measuring.

device used

Inconsistent measurements with identical devices

Mother Nature

Improper Environ & surroundings

Humidity & moisture cause

degradation

Product not stand

sunlight , heat, vibration

Improper environ for workers

“That’s good enough”

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DOWNTIME(Overproduction)

Mindset

Just-In-Case rather

than Just-In-Time

Large batches to

reduce set-up

Men/Women

Lack of training in Lean

Improper staffing/

scheduling

Workers set to

fill up time

Methods

Lean tools like Pull,Kanban not used

Lack of process standardization

Machines

Unreliable machines overproduce until they fail

Old machines need replacement

Materials

Lot sizes require overproduction

Supplier doesn?t employ Lean

Inflexible supplier MOQ

Measurement

Insufficient devices cause flow restriction

Inconsistent measurements necessitate overproduction

to assure quality

Mother Nature

Overproduce to replace spoiled products

Lack of roof/floor maintenance causing leaks and animals inlets

Improper layout leading to damaged products

Improper storage conditions

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DOWNTIME

(Waiting )

Mindset Unnecessary steps

causing delays/idleness

Unnecessary approvals

to proceed

Men/Women

Lack of training causing

delay to proceed in work

Methods Poor line balance cause bottlenecks

Batch processing cause delays in

downstreamMachines

Lack of TPM cause machine failures

Insufficient machines to keep process move

Materials

Inferior material cause delays/stops

Material nonconforming to Specs

Material untimely available

Measurement

Insufficient devices cause process to stop

Old/outdated measuring devices Mother Nature

Undesirable weather conditionsFrequent blackouts

Lack of trust amongst people

Overly cautious policies

Long calibration time

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DOWNTIME(Neglected Resources)

MindsetOutside consultants while

talent exist in -house

Not utilizing newer

s/w or upgrades

Men/Women

Ignored job rotation and

cross -training

Training programs not in

pace with tech and policies

Lack of training on new

resources (e.g. s/w)

Methods

Not on top of technology

Ignored better tech

Newer , more efficient

methods are rejected

Machines

Lack of automation for time -

consuming processes

Compatibility glitches

b/w resources

Materials

Inferior material

lessens productivity

Improper format /specs of

material received by resources

Measurement

Good gauges lay idle in

storage

Mother Nature

Environment prevents use

of good resourcesEnvironment causes

good resources to fail

Mindset not

technologically friendly

Old version of s/w

on machines used

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DOWNTIME(Transportation)

Mindset Documents require

signature are hand -carriedMen/Women

No training on proper use

of material handling equip .

No training on e -communication

instead of manual

Methods

Proper movement of material /info not part of

SOPs

Machines

Improper alignment of machines

in sequential production

Materials

Material requires controlled

environ and transport

Material is bulky to be kept on site

Volume of material delivered

requires sorting and staging

Measurement

Material moved to

measurement labs

Gauges fixed offsite

when they breakdown

Mother Nature

Material moved to proper areas

during improper conditions

Inefficient disaster plan to keep

equipment safe in bad conditions

Products /WIP moved to central staging area

Each job is not supplied with its necessary tools

Multiple emails sent can be

replaced with newsletter

Hand -carried info can be

transported electronically

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DOWNTIME(Inventory)

Mindset Inaccurate material

requirement forecast

Men/Women

Inadequate training on Lean

to control inventory

Methods

Inventory control SOPs not documented/followed

Machines

Machines authorized in batch production causing excessive inventory

Machines with frequent breakdown requiring extra

inventory replacement

Materials

Inferior material requiring quantities more than needed

Large MOQ from suppliers more than needed

Measurement

Inaccurate or non-calibrated meas devices Cause questionable rejects

Resulting in more inventory Mother Nature

Unprotected material damaged requiring

replacement inventory

Just-In-Case overrides JIT thinking

Kanban not used to communicate demands

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DOWNTIME(Motion)

MindsetUnnecessary meetings

Men/Women

No training to perform jobs

with minimal reaching,

bending, searching

Methods

Tools/materials not within ergonomic reach of workers

Machines

Hand tools are used instead of power tools

On/Off and emergency switches not within reach

Materials

Materials need preparation/unwrapping before use

WIP is not oriented to the best reach of next operator

Measurement

Measuring devices require bending/

awkward positioning Mother Nature

Environ. Conditions cause unnecessary motion; e.g.

scattered papers from wind

Workers caused to search for supervisors before they proceed

Desks/workstations not ergonomically designed

Lack of ergonomics practices adoption

No workers involvement in workplace design

Tools/supplies/printers not within reach

Meas. devices are not enough to share

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DOWNTIME(Extra Processing)

Mindset Product inspected by

someone other than worker

Men/Women

Lack of training/

communication cause

duplicate process steps

Methods

No SOPs cause extra polishing steps

Machines

Machining tolerances more than customer needs

Tools/supplies cause workers to perform extra steps to meet specs

Materials

Inferior material require extra preparation before use

Documents contain more info than needed to do a task

Measurement

Inconsistent measuring devices cause additional work

Mother Nature

Environ. Conditions cause extra processing to make product conforming

Product shipped with extra unvalued packaging

Not required packaging by customer

Inspection done at downstream steps instead of source alone

Wrong measuring device cause additional steps or checking more frequently Forms ask for repetitive

info whenever used

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Case Study

Air-Cooled Chiller Assembly Process

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Case Study

Refrigeration Cycle of Air-Cooled Chiller

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Case Study

What is required?

a) Study and understand the process.

b) Process-map the process

c) Identify the wastes in the process

d) Measure the waste

e) Identify the root cause of each waste type

f) Propose a preventive action to the root cause

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Case StudyProcess Analysis-Waste Template (example)

Activity Waste Type Measure Cause Root Cause Preventive Action

Bringing chiller design

paper drawings from

the Design section

Motion 10min Machine Input material not

within reach

Material: soft copies of drawings

received via email

Neglected

Resources

Email/

software

Mindset not utilizing new tech Mindset: utilizing new tech

(email)

Transportation 30m Material Paper need to be

carried from Design to

Assembly

Material: soft copies of drawings

received via email

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