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[Preview] Waste-finding Checklists for Manufacturing Companies

This is a comprehensive set of checklists for waste-finding in manufacturing companies. The checklists are based on the eight types of Lean waste:

1. Overproduction
2. Inventory
3. Waiting
4. Motion
5. Transportation
6. Defects
7. Overprocessing
8. Intellectual

The checklists have a combined total of 65 waste items which could be potentially found on the shopfloor. For each checklist item, the magnitude of waste can be quantified under four levels:

Magnitude 0 : No waste found
Magnitude 1 : Very little waste
Magnitude 2 : Some waste
Magnitude 3 : A lot of waste

The checklists can be applied generally to all manufacturing departments. Users may adopt the checklists as they are, or customize them to suit your specific application. Add or delete the checklist items as needed.

The checklists form the basis of a structured improvement plan. Waste items can be ranked or prioritized and assigned to a person or team to develop an action plan for eliminating the identified waste within a certain timeframe.

CONTENTS:

1. Summary of the Eight Types of Lean Waste
2. Waste-finding Checklists
2.1 Waste-finding Checklist: Overproduction
2.2 Waste-finding Checklist: Inventory
2.3 Waste-finding Checklist: Waiting
2.4 Waste-finding Checklist: Motion
2.5 Waste-finding Checklist: Transportation
2.6 Waste-finding Checklist: Defects
2.7 Waste-finding Checklist: Overprocessing
2.8 Waste-finding Checklist: Intellectual
2.9 Major Waste-finding Checklist

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[Preview] Waste-finding Checklists for Manufacturing Companies

  1. 1. © Operational Excellence Consulting. All rights reserved. Waste-finding Checklists for Manufacturing Companies Checklists for Discovering Wastes in Manufacturing Companies This is a set of checklists for waste-finding in manufacturing companies based on the eight types of Lean wastes: Overproduction, Inventory, Waiting, Motion, Transportation, Defects, Processing and Intellectual.
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 About this document 1. The waste-finding checklists are based on the eight types of lean waste that are commonly found in a manufacturing environment. 2. You may adopt the checklists as they are, or customize them to suit your specific application. Add or delete the checklist items as needed. 3. The checklists form the basis of a structured improvement plan. Waste items can be ranked or prioritized and assigned to a person or team to develop an action plan for eliminating the identified waste within a certain timeframe. 4. To eliminate waste, it is recommended to start with the low hanging fruits and then work progressively toward the major waste or more complicated ones.
  3. 3. © Operational Excellence Consulting. All rights reserved. 3 Contents Summary of the Eight Types of Waste Waste-finding Checklists 1 2
  4. 4. © Operational Excellence Consulting. All rights reserved. Summary of the Eight Types of Waste 1
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 The Eight Types of Lean Waste Over-production Producing more than what the customer needs Inventory Building and storing extra products the customer has not ordered Transportation Moving product from one place to another Defects Reprocessing, or correcting work Over-processing Adding excess value when the customer does not require it Motion Extra physical or mental motion that does not add value Intellect Not using employees’ full intellectual contribution Waiting Employees waiting for another process or a machine/tool Wastes
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 The Eight Types of Waste in a Production System Transportation Processing waste Inventory Defects Overproduction (production methods) Motion waste (operation methods) Waiting time (imbalances) Intellectual waste Retention Inspection Processing Retention Transportation
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 Overproduction § It is the worst of the eight waste § It is the exact opposite of just-in- time production § Overproduction means making what is unnecessary, when it is unnecessary, and in unnecessary amounts § Occurs when you manufacture items when there are no orders
  8. 8. © Operational Excellence Consulting. All rights reserved. 8 Inventory § Overproduction leads to inventory § Inventory means any goods that are being retained for any length of time, inside or outside the factory § Inventory includes raw materials, work-in-process, assembly parts and finished goods § One of the best ways to begin finding waste is to look for retention points where inventory tends to pile up
  9. 9. © Operational Excellence Consulting. All rights reserved. Waste-finding Checklists 2
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 Waste Finding – 4 Levels of Magnitude Magnitude of Waste 0 ------------------ No waste found 1 ------------------ Very little waste 2 ------------------ Some waste 3 ------------------ A lot of waste
  11. 11. © Operational Excellence Consulting. All rights reserved. 11 Waste-finding Checklist – Overproduction Waste-finding Checklist – Overproduction Process: Date: Description of Waste Yes No Magnitude Causes and/or Improvement Plans 1 No production schedule or control boards. 2 No levelling of production schedule. 3 Production not in sync with production schedule. 4 Items missing. 5 Defective goods produced. 6 Equipment breakdowns. 7 Too much manual assistance required. 8 Machines have too much capacity. 9 Lots are grouped into batches. 10 Using “push” production. 11 Caravan style operations. 12 Not balanced with next process. Total
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 Waste-finding Checklist – Inventory Waste-finding Checklist – Inventory Process: Date: Description of Waste Yes No Magnitude Causes and/or Improvement Plans 1 Lots of inventory on shelves and floors. 2 Shelf and floor storage takes up lots of space. 3 Inventory stacks block walkways. 4 In-process inventory accumulates within individual operations. 5 In-process inventory is stacked up between operators. 6 In-process inventory is stacked up between processes. 7 Impossible to visually determine quantities of in- process inventory. Total
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 Waste-finding Checklist – Defects Waste-finding Checklist – Defects Process: Date: Description of Waste Yes No Magnitude Causes and/or Improvement Plans 1 Complaints from next process. 2 Defects within the process. 3 Human errors. 4 Defects due to missing part(s). 5 Defects due to wrong part(s). 6 Omission(s) in processing. 7 Defect(s) in processing. 8 No human automation. 9 No mistake-proofing. 10 No inspection within process. 11 Defects not addressed by improvement activities. Total
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 Waste-finding Checklist – Motion Waste-finding Checklist – Motion Process: Date: Description of Waste Yes No Magnitude Causes and/or Improvement Plans 1 Walking. 2 Turning around. 3 Leaning sideways. 4 Bending over. 5 Too wide arm movements. 6 Unnecessary wrist movements. 7 Left or right hand is idle. 8 Poorly utilized idle time. 9 Wasteful work piece setup/removal. 10 Non-standardized repetition of operations. 11 Worker operates using different motions each time. 12 Operations divided into too many little segments. Total
  15. 15. © Operational Excellence Consulting. All rights reserved. 15 Checklist for Major Waste Finding Checklist for Major Waste Finding Workshop Name: Date: # Process Name 1 2 3 4 5 6 7 8 Waste Magnitude Total Improvement Ranking Improvement Ideas & Comments Overproduction waste Inventory waste Transportation waste Defect waste Processing waste Motion waste Waiting waste Intellectual waste
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg

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