Continuous Improvement Workshop Training

1
The Seven Forms of Waste

• Continuous Improvement focuses on the
  identification and elimination of the 7 forms of
  waste
• Overproduction
• Inventory
• Unnecessary Motion
• Transportation
• Waiting
• Over Processing
• Defects / Repair / Rework

2
1. Over Production

• Producing products or materials before they are
  needed.
• Overproduction is the worst form of waste because
  it is the root cause of many other wastes.
• Results of Over Production
• Products being produced in excess quantities
• Products being made before customers need them
• Excess Inventory
• Excess Transportation
• Hides available capacity
• Caused by
• Working ahead of customer (internal/external)
  or process requirements

3
Waste Of Overproduction Example
OPERATOR SHOULD BE IN THIS STATION (ST 16) BUT IS
WORKING AHEAD IN ST 15
4
2. Inventory

• Excess inventory is not directly required for
  current customer orders.
• Results of Excess Inventory
• requires space
• costs money and ties up capital
• search and transport damage
• hides defects
• excess WIP and finished out-of-date product
• Increased deterioration
• Caused by
• Working ahead of build requirements
• High WIP standards
• No WIP standards
• Lack of JIT/Pull system

5
Excess Inventory Example
STANDARD SET AT 4 HIGH X 3 DEEP
PART BIN STACKED 6 HIGH
6
3. Motion

• Unnecessary movement in a process.
• Some Results of Motion
• unnecessary walking
• poor ergonomic conditions
• part transfer
• reaching and stopping and walking to locate/
  pick up parts/tools
• Caused by
• poor parts placement
• poor process flow
• poor work station layout

7
Waste of Motion Example
TEAM MEMBER IN PAINT SHOP ATTEMPTING TO UNTANGLE
HOSES TO THE BACK-UP GUNS IN THE TOP COAT BOOTH.
8
4. Transportation

• The unnecessary movement of materials
• Results of Transportation
• Loss of traceability
• Damaged goods
• Increased Lead Time
• Excess Costs
• Storage space
• Caused by
• Poor parts storage
• Poor Work area layouts
• Working ahead of build requirements
• Lack of JIT/ Pull system

9
Waste of Transportation Example
BODY SHOP CONVEYANCE DELIVERS AMS BRACKETS TO
TABLE ON THE FLOOR
BODY SHOP T/M CARRIES PARTS TO RACK LINESIDE.
10
5. Waiting

• Periods of inactivity in a downstream process
  that occur because an upstream activity does not
  deliver on time.
• Results of Waiting
• Over Production
• Over Processing
• Idle resources
• Non-Value added work
• Caused by
• Line stops
• Waiting for Material
• Repair/Maintenance
• Waiting for equipment to process
• Missing tools
• Non- Full work process

11
Waste of Waiting Example
TEAM MEMBER WAITING ON BODY IN ST. 3900. ROBOTS
IN ST. 2400 WENT DOWN CAUSING DOWNTIME
12
6. Over Processing

• Producing more or better than the customer
  requires.
• Results of Over Processing
• Increased Processing Time
• Costs
• Incorrect process/equipment
• Caused by
• Refining the product in ways or areas not
• important to the customer
• Wait Time
• Unclear Quality Standards

13
Waste of Over Processing Example
BODY SHOP T/M SANDING DOOR THAT HAD NO DEFECTS
14
7. Defects/Repair/Rework

• Products or aspects of the production processes
  that do not conform to specifications or to the
  customers expectations.
• Results of Defects/Repair/Rework
• Customer Dissatisfaction
• Non-Value added work
• Extra costs
• Extra space
• Extra inspections/checks
• Caused by
• Scrapped parts
• Wrong or defective tools or machines
• Wrong or missing processes
• Poor Problem Solving
• Unclear Standards

15
Waste of Repair Example
PAINT SHOP T/M MAKING REPAIR IN SPOT REPAIR BOOTH.