7 deadly wastages in production or manufacturing

1. © ABSL Power Solutions 2007© STM Quality Limited
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Limited
7 Wastes
TOTAL QUALITY MANAGEMENT
7 Wastes
PRESENTED BY:
MD.FURKAN UDDIN JEWEL

2. © STM Quality Limited
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3. © STM Quality Limited
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How often have you used the
expressions:
“That was a waste of time!”
or
“That was a waste of money!”
or
“That was a waste of effort!”
Waste

4. © STM Quality Limited
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LimitedWasted Time
Just imagine if
we could collect
all the time
together that we
have wasted in
the past -
How much time
would that be?

5. © STM Quality Limited
STM Quality
LimitedWasted Money
Just imagine if
we could collect
all the money
together that we
have wasted in
the past -
How much
money would
that be?

6. © STM Quality Limited
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LimitedWasted Effort
Just imagine if
we could collect
all the effort
together that we
have wasted in
the past -
How much effort
would that be?

7. © STM Quality Limited
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LimitedThe Problem With Waste
The problem with wasted time, money &
effort is:
When it’s gone…
- it’s gone!

8. © STM Quality Limited
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LimitedEliminating Waste
So what can we do to eliminate
waste?
We first need to identify what is &
is not waste, then we can look at
ways of eliminating or at least
reducing waste.

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Identifying Waste in the
Workplace
Operational Activity
Value added Operations
Any process that changes the nature,
shape or characteristic of the product in
line with customer requirements
e.g. Pressing, welding, heat treatment.
This is where we make a profit!

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Identifying Waste in the
Workplace
Operational Activity
Non-Value added Operations
Work carried out which is necessary under
current conditions, but does not increase
product value.
e.g. Inspection, tool change, maintenance.
This is where we make a loss!

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Value Added and
Non-Value Added operations
The objective is to raise the ratio of Value
added operations to non-value added
operations and eliminate waste.
WASTE NON-VALUE ADDED
VALUE
ADDED
OPERATOR TIME
VALUE
ADDED
NON-VALUE
ADDED
MORE TIME FOR
OTHER ACTIVITIES
ELIMINATE

12. © STM Quality Limited
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Limited7W – The Elimination of Waste
So, now we understand the difference in
value added & non-value added
operations, what are the benefits in
eliminating all waste?
• Reduced costs
• Greater Capacity
• Bottlenecks are identified

13. © STM Quality Limited
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Limited7W – 7 Types of Waste
1 Over-production
2 Inventory
3 Transportation
4 Process
5 Idle Time
6 Operator Motion
7 Bad Quality

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15. © STM Quality Limited
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The seven wastes or Muda can be
remembered through the use of either of
the two mnemonics; TIMWOOD
1) Transport
2) Inventory
3) Motion (Operator )
4) Waiting
5) Over-production
6) Over-Processing
7) Defects or Bad Quality

16. © STM Quality Limited
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Limited7W – 1. Over-production
Over-production
Producing more than is needed hides a
multitude of problems. Excessive set-up times,
machine faults, risk of producing obsolete
stock.

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18. © STM Quality Limited
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Limited7W – 2. Inventory
Inventory
Carrying stock attracts cost & storage problems.
Storage leads to stacking, racking,
sophisticated computers, bar coding &
automation, all for an activity that adds no value
to the product.

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20. © STM Quality Limited
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Limited7W – 3. Transportation
Transportation
This may appear unnecessary but does add
value. Large transport is easily identified but
small transport such as manual labour may not
be so noticeable. These can be improved by
changes to the work environment.

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22. © STM Quality Limited
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7W – 4.
Process
Process
Adds cost but no value - e.g.trimming &
moulding to a level that is beyond the required
standard adds extra time that customers do
not want to pay for.

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24. © STM Quality Limited
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7W – 5. Idle
Time
Idle Time
Typically, waiting for products & services from
preceding operations, waiting for work from
their previous set-up or waiting for cycles to
finish, or meetings to start.

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26. © STM Quality Limited
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Limited7W – 6. Operator Motion
Operator Motion
Typically, single handed operations where
both should be used, stretching unnecessarily
or awkwardly and walking between things. All
of these take time or use time poorly, none
add value.

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28. © STM Quality Limited
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Limited7W – 7. Bad Quality
Bad Quality
Rejects are always produced by systems and
procedures created by management. If
operators fail it is because the process allowed
them to fail through inadequate training or
because the process was not capable in the
first place.

29. © STM Quality Limited
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30. © STM Quality Limited
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7W – The Elimination of
Waste
So, now we understand the 7 wastes, we can:
• Produce only what is needed;
• Carry only essential stock;
• Use transportation more wisely;
• Produce work to the standard required;
• Plan our production processes;
• Put our efforts to the best possible use;
• Train to make quality work every time!