WASTE DEFINATION CHARACTERISTICS CAUSES SOLUTION

1.Extra Manpower 1.Incapable 1.Implement pull system

Over Producing more than 2.Unbalanced Material Flow 2.Processes 2.Controlled stock
Production needed
3.Excessive Storage 3.Just in Case Reward
System

Movement of Material that 1.Multiple Storage Locations 1.Lack of Visual 1.Level schedule
not directly support a lean Controls
Conveyance Manufacturing system. 2.Complex Inventory Management 2.Proper facility
2.Large Lot
3.Incorrect Inventory Counts Processing

1.Man Waiting for Machine 1.Inconsistent Work 1.Reduce queue

Products are not moving for Methods Size
Waiting next process 2.Machine/Materials Waiting for Man
2.Low Man/Machine 2.Improving
3.Unbalanced Operations Effectiveness Planning and Load Levelling

1.Lack of Clear Customer 1.Lack of Customer 1.Smaller machine avoid bottle

Specifications necks
Over Process which adds no 2.Input Concerning
processing value to a product or 2.Redundant Approvals Requirements 2.Clear customer specification
service. of product.
3.Decision Making at
Inappropriate Levels

1.Long Lead Time for Engineering 1.Incapable Suppliers 1.Adjust the production with
Excess supply of raw Changes demand
Inventory material to produce products 2.Long Change Over
just in time 2.Additional Material Handling Times
Resources

1.Material Too Far Apart 1.Lack of Visual 1.Introduction of work-cells

Movement of people which Controls
Motion does not contribute added 2.Excessive Reaching 3.Bending 2.Shadow boards
value to the product Equipment for Moving Parts 2.Inconsistent Work
Methods

1.Extra Manpower To 1.Insufficient Training 1.Root Cause

Repair of a product or Inspect/Rework/Repair Analysis
Correction service to met customer 2.Unnecessary
requirements 2.Missed Shipments/Deliveries Handling 2.Error
Proofing
3.Questionable Quality

SEVEN METHODS OF WASTE