APPENDIX C WASTE IN THE ENTERPRISE Table c1 PRODUCTION WASTE Table c2 INFORMATION WASTE Table c3 ENTERPRISE LEVEL WASTE Table C 4 ENTERPRISE WASTE TAXONOMY Enterprise Level Waste 10/20/200
APPENDIX C WASTE IN THE ENTERPRISE Table C.1 PRODUCTION WASTE Table C.2 INFORMATION WASTE Table C.3 ENTERPRISE LEVEL WASTE Table C.4 ENTERPRISE WASTE TAXONOMY Enterprise Level Waste 10/20/2002 6
TABLE C 1 PRODUCTION WASTES TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Employee waiting for Idle time in which· tooling Poor scheduling work coordination no value is added equipment repair. Inadequate preventive maintenance uality inspector. Lack of employee empowermer · material machine to· Push system complete operation. One employee assigned to each machine Machine waiting for owing o same equipment repair. same · quality inspector|·same employee Inattention; poor scheduling; unbalanced operations; no back-up or cross training of co-workers set-up changeover. Long set-up times; monolithic equipment Production order machine availability. Push system; unbalanced operations transport to next. Poor coordination; functional process layout operation Enterprise Level Waste 10/20/2002
TABLE C.1 PRODUCTION WASTES TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Waiting Idle time in which no value is added Employee waiting for • tooling • equipment repair • quality inspector • material machine to complete operation • Poor scheduling, work coordination • Inadequate preventive maintenance • Lack of employee empowerment • Push system • One employee assigned to each machine Machine waiting for • tooling • equipment repair • quality inspector • material • employee • set-up changeover • same • same • same • same • Inattention; poor scheduling; unbalanced operations; no back-up or cross training of co-workers • Long set-up times; monolithic equipment Production order waiting for • machine availability • transport to next operation • Push system; unbalanced operations • Poor coordination; functional process layout Enterprise Level Waste 10/20/2002 7
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Materials/ tools moved. Batch and queue(push)syste Excessive move etween functionally Functional process layout ment of material, grouped equipment or. Monolithic equipment/prc tools or parts processing centers, or. Irrational facility/site locations between different Production orders Push system; poor layout moved to and from stores Finished items moved. Traditional hierarchical distribution system through multi-level distribution channels Enterprise Level Waste 10/20/2002
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Transportation Excessive movement of material, tools or parts Materials/tools moved between functionally grouped equipment or processing centers, or between different facilities/sites • Batch and queue (push) system • Functional process layout • Monolithic equipment/processes • Irrational facility/site locations Production orders moved to and from stores • Push system; poor layout Finished items moved through multi-level distribution channels • Traditional hierarchical distribution system Enterprise Level Waste 10/20/2002 8
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Over-processing Work that could be. Poor product design Effort expended combined with other. Poor process planning/manufacturing engineeri which does not operations via fewer add customer individual parts or multiple operations on same equipmen Work performed on. Improperly sized equipment; poor maintenance; poor instruc wro ong-sized equipment, and training running time, or excess perating costs Enhancements Lack of clear customer requirements; tendency for engineers to precision beyond over-desigr customer needs aproper material Rework Excessive testing Poor product/process design; lack of qualified performance certification system Enterprise Level Waste 10/20/2002
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Over-processing Effort expended which does not add customer value Work that could be combined with other operations via fewer individual parts or multiple operations on same equipment • Poor product design • Poor process planning/manufacturing engineering Work performed on wrong-sized equipment, requiring excess running time, or excess operating costs • Improperly sized equipment; poor maintenance; poor instructions and training Enhancements, precision beyond customer needs • Lack of clear customer requirements; tendency for engineers to over-design Improper material • Lack of current knowledge of alternative material capabilities Rework • Inadequate preventive maintenance; lack of automated process controls; poor workmanship Excessive testing • Poor product/process design; lack of qualified performance certification system Enterprise Level Waste 10/20/2002 9
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Inventoried Excessive raw materials. Maintaining stocks of materials in excess of current production requirements; inadequate selection of suppliers; lack of JIT materials beyond discipline in supply base; lack of coordination with suppliers JITrequirements inaccurate inventory records Excessive finished Push system; building to forecast; multi-level distribution system production to maintain employment level Push system; batch and queue; buffers between unsynchronized progress production operations; high variability in process times; "lost Obsolete and out-of Waiting too long to dispose, frequent design changes; production parts and undisciplined configuration management; lack of understanding of materials sunk cost Enterprise Level Waste 10/20/2002
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Inventories Accumulations of materials beyond JIT requirements Excessive raw materials and supplies • Maintaining stocks of materials in excess of current production requirements; inadequate selection of suppliers; lack of JIT discipline in supply base; lack of coordination with suppliers; inaccurate inventory records Excessive finished goods • Push system; building to forecast; multi-level distribution system; production to maintain employment level Excessive work in progress • Push system; batch and queue; buffers between unsynchronized production operations; high variability in process times; “lost” production orders Obsolete and out-ofproduction parts and materials • Waiting too long to dispose; frequent design changes; undisciplined configuration management; lack of understanding of “sunk cost” • Enterprise Level Waste 10/20/2002 10