[Note: This is a partial preview. To download this presentation, visit: https://www.oeconsulting.com.sg/training-presentations] 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

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. © 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. © Operational Excellence Consulting. All rights reserved. 3
Contents
Summary of the Eight Types of Waste
Waste-finding Checklists
1
2

4. © Operational Excellence Consulting. All rights reserved.
Summary of the Eight
Types of Waste
1

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. © 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. © 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. © 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. © Operational Excellence Consulting. All rights reserved.
Waste-finding Checklists
2

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. © 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. © 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. © 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. © 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. © 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. © 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