TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Unnecessary Excessive reaching,. Poor work design; lack of standard methods, poor work-space otion ending, stretching ny human move ment that doe not add value Searching for tools poor facility design, poor housekeeping and Excessive walking for or design, poor tool and material access materials Excessive handling of. Lack of one-piece flow, lack of cellular layout; stop and go work pieces Excessive force, energy. Poor work design; lack of ergonomic standards, poor part desigr required for operations Long set-up times Lack of disciplined set-up minimization effort Enterprise Level Waste 10/20/2002
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Unnecessary Motion Any human movement that does not add value Excessive reaching, bending, stretching • Poor work design; lack of standard methods; poor work-space design Searching for tools, parts, materials • Poor layout; poor facility design; poor housekeeping and organization Excessive walking for tools, parts, materials • Poor facility design; poor tool and material access Excessive handling of work pieces • Lack of one-piece flow; lack of cellular layout; stop and go processing Excessive force, energy required for operations • Poor work design; lack of ergonomic standards; poor part design Long set-up times • Lack of disciplined set-up minimization effort Enterprise Level Waste 10/20/2002 11
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Product Defects Defects occurring in. Poor process capability; poor standard operation specifications Iny item that internal production adequate training and instruction; lack of consideration of does not meet capability during product design phase; lack specific Defects occurring in. Inadequate quality certification/verification regimen supplier parts/materials Defects occurring Iring final test Defects discovered by customer after delivery Enterprise Level Waste 10/20/2002
TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Product Defects Any item that does not meet specifications Defects occurring in internal production • Poor process capability; poor standard operation specifications; inadequate training and instruction; lack of consideration of process capability during product design phase; lack of mistakeproofing discipline Defects occurring in supplier parts/materials • Inadequate quality certification/verification regimen Defects occurring during final test • Defects discovered by customer after delivery • Enterprise Level Waste 10/20/2002 12