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ACCU BEKAS: 7 Wastes of Production

ACCU BEKAS

Jumat, 16 Januari 2009

7 Wastes of Production

7 Wastes of Production


Taiichi Ohno defined the 7 types of waste that describe all activity that adds cost but not value. In a Lean Enterprise these 7 types of “Muda” are the target of an endless pursuit of waste elimination. Learning to see “Muda” all around you is the key to starting out on your journey of transforming your organization into a Lean Enterprise.

The 7 Wastes – “Muda”

Definition

Examples

Causes

Countermeasures

Overproduction

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

  • Just in case” for breakdowns

  • Pull system scheduling

  • Heijunka – level loading

  • Set-up reduction

  • TPM

Transportation

Movement of product that does not add value

  • Moving parts in and out of storage

  • Moving material from one workstation to another

  • Batch production

  • Push production

  • Storage

  • Functional layout

  • Flow lines

  • Pull system

  • Value Stream organizations

  • Kanban

Motion

Movement of people that does not add value

  • 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

  • Point of Use Storage

  • Water Spider

  • One-piece flow

  • Workstation design

Waiting

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

  • Push production

  • Work imbalance

  • Centralized inspection

  • Order entry delays

  • Lack of priority

  • Lack of communication

  • Downstream pull

  • Takt time production

  • In-process gauging

  • Jidoka

  • Office Kaizen

  • TPM

Processing

Effort that adds no value from the customer’s viewpoint

  • Multiple cleaning of parts

  • Paperwork

  • Over-tight tolerances

  • Awkward tool or part design

  • Delay between processing

  • Push system

  • Customer voice not understood

  • Designs “thrown over the wall”

  • Flow lines

  • One-piece pull

  • Office Kaizen

  • 3P

  • Lean Design

Inventory

More materials, parts, or products on hand than the customer needs right now

  • Raw materials

  • Work in process

  • Finished goods

  • Consumable supplies

  • Purchased components

  • Supplier lead-times

  • Lack of flow

  • Long set-ups

  • Long lead-times

  • Paperwork in process

  • Lack of ordering procedure

  • External kanban

  • Supplier development

  • One-piece flow lines

  • Set-up reduction

  • Internal kanban

Defects

Work that contains errors, rework, mistakes or lacks something necessary

  • Scrap

  • Rework

  • Defects

  • Correction

  • Field failure

  • Variation

  • Missing parts

  • Process failure

  • Mis-loaded part

  • Batch process

  • Inspect-in quality

  • Incapable machines

  • GembaSigma

  • Pokayoke

  • One-piece pull

  • Built-in quality

  • 3P

  • Jidoka


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