Companies are always looking for new ways to improve business efficiency and increase quality. To run a business at optimal capacity, you need to reduce or eliminate waste from processes and improve production flow. In this course, you’ll learn about Lean strategies to reduce waste by determining which operations add value and which don’t. You’ll explore the concept of continuous flow, and discover how to balance work processes to make production flow more efficient. You’ll define what waste is, where it exists, and what causes it. You’ll also examine aspects of Muda, continuous flow, line balancing, value and non-value-add, and practical Lean techniques for improving Operations Management.
What is waste in Lean Manufacturing?
A core principle in lean methodology is the removal of waste within an operation. And in any business, one of the heaviest drains on profitability is waste. Lean waste can come in the form of time, material, and labor. But it may also be related to the utilization of skill-sets as well as poor planning. In lean manufacturing, waste is any expense or effort that is expended but which does not transform raw materials into an item the customer is willing to pay for. By optimizing process steps and eliminating waste, the only true value is added at each phase of production.
Today, the Lean Manufacturing model recognizes 8 types of waste within an operation; seven originally conceived when the Toyota Production System was first conceived, and an eighth added when the lean methodology was adopted within the Western World. Seven of the eight wastes are production process-oriented, while the eighth waste is directly related to management’s ability to utilize personnel.
WHAT YOU WILL LEARN to
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classify production activities as a value-add, non-value-add, or necessary non-value-add.
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identify strategies for eliminating waste caused by overproduction and inventory.
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identify strategies for eliminating motion, waiting, and transportation waste.
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identify elimination strategies for waste caused by overprocessing and defects
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match cycle time and takt time to their descriptions
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identify the final three steps for balancing a production line
Resources
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1-The Concept of Wastewaste is a core principle in lean methodology: the removal of waste within an operation. And in any business, one of the heaviest drains on profitability is waste.
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2-Waste Categories
once you become familiar with the type and categories of waste, you will know where the waste exists more or less everywhere. and easily you will identify opportunities for improvement. So, once you identify the waste, you can improve that process by reducing or eliminating that waste.
we have three categories of waste:
Muda.
Mura.
Muri.
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3-Types Of Waste
This acronym shows all seven types of waste other than the last one, which was the underutilization of people and machines.
Defects.
Overproduction.
Waiting.
Non-utilized talent.
Transportation.
Inventory.
Motion.
Extra-processing.
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4-Defects Waste
Refer to a product that deviates from the standards of its design or from the customer’s expectation.
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5- Overproduction Waste
when manufacturing a product or an element of the product before they are required by the next downstream process, overproduction occurs.
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6- Waiting Waste
Waiting may also trigger additional waste in the form of defects if the waiting triggers a flurry of activity to “catch up” that results in standard work not being followed or shortcuts being taken.
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7- Non-Utilized Talent Waste
it is the Waste of unused human talent and ingenuity.
it was not a part of the Toyota Production System (TPS), as it is human potential waste,not a manufacturing-process specific like other wastes,
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8-Transportation Waste
Transportation waste is any unnecessary movement of people, tools, inventory, equipment, or products further than necessary.
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9-Inventory waste
Most of the time, it is difficult to think about excess inventory as waste.
In accounting, inventory is seen as an asset and oftentimes suppliers give discounts for bulk purchases.
Inventory is considered a form of waste because of the related holding costs.
That is why Over purchasing or poor forecasting and planning can lead to inventory waste also it is a signal a broken or poorly designed process link between manufacturing and purchasing/scheduling
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10-Motion Waste
All unnecessary motion results in non-value-added time and increases cost. That is why Tasks that require excessive motion should be redesigned to enhance the work of personnel and increase the health and safety levels
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11-Over-Processing Waste
Over-processing refers to doing more work, adding more components, or having more steps in a product or service than what is required by the customer.
