Waste is an awful word that devalues quality, manufacturing processes, and your business’ bottom line. In most cases, you’ve put a lot of effort into lean manufacturing principles - striving to work towards eliminating waste. Did the 5S principles work? Or is it time to clear the dust and re-valuate the steps you took to eliminate seven deadly wastes?
If you feel as though waste has crept back into your workplace and you’re not sure what to do about it, here are some tips. We’ll help you identify the seven deadly wastes, and offer some tips to help your kick them to the curb once and for all.
Defects – Defects are a direct result of both human error and improper machinery. Defects create products that can’t be sold to consumers and require the product to be scrapped or reworked.
Overproduction – Overproduction is the production of goods in higher levels and numbers than what is needed. In other words, making products before they’re needed or making more product than what is required to fill an order. Overproduction will create excess inventory, which takes up space.
Waiting - Waiting is when work-in-process stops until the next step is completed or provided to the manufacturer. Waiting prevents the completion of a product. Often times, a product is waiting for raw material or component parts before it can move through the process of completion.
Transportation – Transportation is the unnecessary movement of raw materials through manufacturing processes.
Inventory – Inventory involves any products that go beyond supporting the immediate need. Is stock depleted, overflowing, or outdated?
Motion – Motion refers to the unnecessary movement of people that doesn’t add value. Think of a worker walking away from his/her work station to grab something across the plant in order to effectively complete their job.
Extra Processing – Extra processing is often known as one of the most difficult wastes to detect and eliminate. Over processing is over producing orders.
Bonus step: Non-Utilized People – When you’ve re-evaluated the process of lean manufacturing and implemented proper solutions to problems, some of the tedious jobs become non-existent. Eliminate underutilized people in your workplace by developing strong coaching skills for management so they know where to place employees for effective contributions to your business.
Contact the the5sstore for solutions and 5S best practices.
Find the 8 Waste poster here.