Review Table 6.1 - The Eight Types of Waste or Muda in Chapter 6

Give four detailed examples of Waste in a business (all FOUR do not have to be from one business process)

How would you as a manager use the Lean Systems Approach to solve the FOUR Waste problems?

TABLE 6.1 THE EIGHT TYPES OF WASTE OR MUDA' Waste Definition 1. Overproduction Manufacturing an item before it is needed, making it difficult to detect defects and creating excessive lead times and inventory. 2. Inappropriate Processing Using expensive high-precision equipment when simpler machines would suffice. It leads to overutilization of expensive capital assets. Investment in smaller flexible equipment, immaculately maintained older machines, and combining process steps where appropriate reduce the waste associated with inappropriate processing. 3. Waiting Wasteful time incurred when product is not being moved or processed. Long production runs, poor material flows, and processes that are not tightly linked to one another can cause over 90 percent of a product's lead time to be spent waiting. 4. Transportation Excessive movement and material handling of product between processes, which can cause damage and deterioration of product quality without adding any significant customer value. 5. Motion Unnecessary effort related to the ergonomics of bending, stretching, reaching, lifting, and walking. Jobs with excessive motion should be redesigned. 6. Inventory Excess inventory hides problems on the shop floor, consumes space, increases lead times, and inhibits communication. Work-in-process inventory is a direct result of overproduction and waiting. 7. Defects Quality defects result in rework and scrap and add wasteful costs to the system in the form of lost capacity, rescheduling effort, increased inspection, and loss of customer goodwill. 8. Underutilization of Employees Failure of the firm to learn from and capitalize on its employees' knowledge and creativity impedes long-term efforts to eliminate waste. 'David McBride, "The Seven Manufacturing Wastes, " August 29, 2003, http://www.emsstrategies.com by permission of EMS Consulting Group, Inc. @ 2003