Kaizen principles has have highlighted seven wastes in production line where comapnies looses out time , money and productivity .Manufacturers have to eliminate these deadly wastes with modification ,low cost automation and asking question whether customer would pay for the activity involved at shop floors .
Here are the seven waste in any manufacturing unit
Normaly most of the manufacturers adopt these principles which works in push system rather than pull system where production is plan in batch and items are produced in excess to be kept as inventory .Reasons for Over production could be non- availability of machines , wrong sales forecast stock out of certain raw material , high change over time .Over production results in waste of money which could have been used for other useful activity. Stocks gets deterioted if kept for longer time . Few Examples are
Producing more than the customer needs right now Producing product to stock based on sales forecasts Producing more to avoid set-ups Batch process resulting in extra output Forecasting Long set-ups
Solution could be Pull system scheduling,Heijunka – level loading,Set-up reduction
Now this could be a finished product waiting for dispatch , items waiting for the next phase on the production line or raw material procured in advance for any reason .Thus blocking companies money .Few Examples for waiting are . Called Muda in Kaizen Concepts
Idle time created when material, information, people, or equipment is not ready
Waiting for parts Waiting for prints Waiting for inspection Waiting for machines Waiting for information Waiting for machine repair
Solution could be Takt time production,In-process gauging,Jidoka,Office Kaizen,TPM
This is due to wrong layout of the production flow as objetcs are kept at distance which has to be moved to production shop floor resulting in waste ( time , labour and cost ) . Care should be taken such that the time spent on transporting items to or from warehouse is minimum.Better examples are work stations in any automobile company where every thing is delivered at work station.Low automation on loading , unloading and transporting can save good amount of money .
Movement of product that does not add value Moving parts in and out of storage
Moving material from one workstation to another Batch production
Solution could be Pull system,Value Stream organizations
In appropriate processing comes into picture when manufacturers goes for advance hitech machinery for normal job which could have done by conventional machine. These highly automated machines if not handled carefully tends to over produce .This also includes items sourced from a wrong supplier .
This happens due to faulty production planning,long lead times also contributes on inventory, long set up time .,Overproduction of finished good ,WIP .This also happens due lack of proper ordering procedure based on EOQ .
Solution Supplier development,One-piece flow lines,Set-up reduction,Internal kanban and External kanban
Normaly it is about ergonomics the worker s posture which results in unecessary motion or few jobs which are done repetitively without adding any value to the job.
Searching for parts, tools, prints, etc. Sorting through materials Reaching for tools Lifting boxes of parts Workplace disorganization Missing items Poor workstation design Unsafe work area 5S
Solution could be Point of Use Storage,Water Spider,One-piece flow,Workstation design
Defects are shear waste and has to minimised to zero as these are cost to company defective products cosumes raw material fuel labour .Cost is incurred on rework on these defectives .
Variation Missing parts Process failure Mis-loaded part Batch process Inspect-in quality Incapable machines