The Seven Mudas

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The Seven Mudas

• Scott Hudson
• Jason Jones
• Kim Horn

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Definition of Muda

• Is simply defined as waste
• More specifically, any human activity which
  absorbs resources but creates NO value
• Waste absorbs both time and money, causing
  inefficiency

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Taiichi Ohno

• Top Toyota Executive
• The father of Toyota Production System, JIT, and
  Lean Manufacturing
• Identified the 7 types of Mudas

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7 Categories of Waste

• 1. Overproduction
• 2. Waiting
• 3. Transporting
• 4. Inappropriate Processing
• 5. Unnecessary Inventory
• 6. Unnecessary Motion
• 7. Defects

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1. Overproduction

• Making too much
• Producing too early
• Making it just in case
• Considered the most serious of the 7 wastes

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2. Waiting

• When time is not used effectively
• Any time materials or components are not moving
  or adding value

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3. Transporting

• Movement of materials within a factory
• The number of movements is directly proportional
  to the opportunity for damage and deterioration

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4. Inappropriate Processing

• Machines and processes that are not capable of
  quality output

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5. Unnecessary Inventory

• Inventory exceeding specified quantity limit
• The enemy of quality and productivity

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6. Unnecessary Motion

• Refers the ergonomics of the workplace
• Too much bending, reaching, walking, or moving to
  do the job

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7. Defects

• Internal and external failures
• Scrap, rework, less than perfect yield, complaints

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7 Categories of Waste

• A standard against which to measure continuous
  improvement efforts of many organizations
• Helps to develop lean manufacturing

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Waste

• Waste is everywhere
• Solved through lean thinking
• Lean Thinking elimination of all forms of waste
  from an operation

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Reasons to eliminate waste

• To maximize your opportunity to have a
  significant financial impact on your business
• To avoid high operating and production costs that
  are ultimately passed on to the customer
• To keep your customers its cheaper to retain a
  customer than to acquire one
• Dont throw money away!!

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8 more forms of Waste

• 1. Information
• 2. Untapped Human Potential
• 3. Inappropriate Systems
• 4. Energy and Water
• 5. Materials
• 6. Service and Office
• 7. Customer Time
• 8. Defecting customers

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1. Information

• Figuring out what to do and when to do it
• Should not take very much time
• Should not require double checking

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2. Untapped Human Potential

• The power of using the thoughts of all employees
  not just managers
• Create/develop thinking people

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3. Inappropriate Systems

• Remove waste before automating anything
• Include manual as well as computerized systems
• Record keeping

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4. Energy and Water

• Energy management from a human
• Shutting down the machine
• Fixing steam leaks
• Shutting off unnecessary lighting
• Turning off a dripping faucet

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5. Materials

• Conserving materials during design, manufacture,
  customer usage, and more
• Recovery, remanufacturing, and recycling

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6. Service and Office

• Excess photocopying
• Copies in triplicate
• Wasted food
• Unnecessary meetings
• Excess emails
• Overly fancy presentations

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7. Customer Time

• Forced to wait in value-adding services
• Customer inconvenience waiting for a delivery or
  traveling for a service not offered locally

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8. Defecting Customers

• Loss of existing customers resulting from
• Poor service
• Poor quality
• High costs
• Late deliveries

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The 7 Mudas

• Take into account the 7 Mudas AND the next 8
  waste categories to
• Continuously improve
• Maximize your oppurtunity to have a significant
  financial impact on your business

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The 7 Mudas

• If these waste categories are ignored will cause
• Higher operating costs
• Higher production costs
• These costs will eventually be passed on to the
  customers

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The 7 Mudas

• Overcoming the problems of waste will enable you
  to become a lean manufacturer
• Utilizing Lean, Kaizen, JIT, and 5S will help you
  to eliminate waste
• Waste needs to be continuously eliminated

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Conclusion

• Thank You!!