Transportation Unnecessary movements of products & materials. Inventory Excess products and materials not being processed. Motion Unnecessary movements by people (e.g., walking). Waiting Wasted time waiting for the next step in a process. Knowledge disconnection Underutilizing people’s talents, skills & knowledge Defects Efforts caused by rework, scrap, and incorrect information. Overproduction Production that is more tan needed or before it is needed. Overprocessing More work or higher quality tan is required by the customer. Value-adding: 5% Muda: 95%
Muda Motion Work Actual work Auxiliary work
Lean Activities
Standardization Stability Just in time Jidoka Involvement. Flexible, motivated team members continually seeking a better way Goal customer focus: Highest quality, lowest cost, shortest lead time by continually eliminating muda
Standardization Stability Flow Heijunka Takt time Pull System Kanban Visual order Robust process involvement Just in time Jidoka Involvement. Standardized work 5´S TPM Kaizen Circles Suggestion Safety Activities Hoshin Planning Goal customer focus: Hoshin planning, takt, heujinka Involvement, lean design, A3 thinking Poka-Yoke Zone control Visual order (5’s) Problem solving Abnormality control Separate human and machine work involvement Standardized work, Kanban, A3 thinking Visual order (5´S) Hoshin planning Standardized work, 5´S, Jidoka TPM, Heijunka, Kanban