The Seven Deadly Wastes Course Objectives

Learn what the Seven Deadly Wastes are and how they affect our business. Identify the Waste in our business and develop an action plan to eliminate it. Develop an action plan to teach others what the Seven Deadly Wastes are and how to eliminate them.

First The History Lesson

Have you heard of Mass Production? This method of production was brought to the forefront with Henry Fords invention of the automobile.Mass Production Lean Manufacturing

Skilled Craftsmanship

1900s

1930s

1960s

TODA Y

Dr. Deming Enters the SceneFollowing WWII, the lean manufacturing approach was developed by American Dr. Edward Deming, to assist the Japanese economy in rebuilding from the impacts of war. The scarcity of raw materials provided the basic premise for lean manufacturing, i.e., use what is on hand in the most efficient manner.

Great Cars from Japan?How were the first cars from Japan viewed?

How are cars from Japan viewed today? Welcome the age of Lean Manufacturing.

The Toyota Production System

In the early 1960s TPS was pioneered by Taiichi Ohno to reflect the philosophies of waste elimination and time management Highly skilled work cell jobs Emphasis on quality and efficiency

TPS Top Three1.

2.

3.

The team must embrace a philosophy of having zero tolerance for waste Activity on a daily basis is focused on creating a stable production environment. Systems are set up to create customer Pull or Just-in-Time Delivery

Zero Tolerance For Waste

All unnecessary waste can be eliminated

Stated simply, the goal is perfection

Stable Production Environment

The highest quality product can only be achieved in a stable environment. Problems are instabilities that must be surfaced quickly and solved permanently Standardization, consistency and predictability and repeatability are the goals. Improve from there!

Customer Pull/JIT Delivery

A product should only be built to meet customers demands. Build only what the customer wants, deliver it when it is expected and with perfect quality This approach results in the best use of the companys resources, which leads to greater profitability

Lets get into the Waste

What are you willing to pay for?

Dough, Sauce, Toppings, Toppings dropped on the floor, Labor cost for delivery driver, Labor cost for delivery driver to stop at girlfriends house on the way? What are our customers willing to pay for?

VALUE ADDED ACTIVITY

Value Added ActivityValue is added to a product when it changes the fundamental nature of the product. Examples:

Stamping a bracket out of a coil of steel

All other activities are non-value added or waste

And here they are . . .1. 2. 3. 4. 5. 6. 7. Overproduction Inventory Transportation Waiting Motion Over Processing Correction or Rework

WASTE

OverproductionOverproduction is making more of something than the customer requested

Examples:

Running a machine for 16 hours when only 10 are required Making 2 days worth of product when only 1 days worth is required

InventoryInventory waste occurs when there is more product on hand than the customer requested.

Examples:

More raw material than needed for smooth production More work-in-process

TransportationTransportation waste is moving the product more than is necessary

Examples:

Having three storage locations for the same material Moving raw materials to an offsite warehouse

WaitingAnytime value cannot be added because of a delay is defined as the waste of waiting

Examples:

Waiting for material Waiting for a machine to be fixed Unbalanced assembly sequence

MotionThe waste of motion refers to any extra movement of the operator when they are performing the work sequence (excessive or repetitive motion also increases ergonomic issues)

Examples:

Walking 10 feet to retrieve a part or tool Twisting around to grab a part in the back of the workstation

OverprocessingOver processing is doing more to the product than the customer requested

Examples:

Plating a product for four hours when only two are required Testing a product three times when the specification calls for one test

Correction/ReworkAnything that is not done right the first time and requires rework inspection or touchup (Also includes scrap and appearance issues )

Examples:

Re-torquing a bolt Sorting incoming materials Checking a key dimension Trimming thread or flash from a component

Waste in my cell!!Correction Overproduction

Transportation

Waiting

Over Processing

Motion

Inventory

Action Plan for Eliminating Waste and Teaching Others1. 2. 3.

4.5.

Discuss this with my coach.