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© ABSL Power Solutions 2007© STM Quality Limited
STM Quality Limited
7 Wastes
TOTAL QUALITY MANAGEMENT
7 Wastes
© STM Quality Limited
STM Quality Limited
How often have you used the expressions:
“That was a waste of time!”or
“That was a waste of money!”or
“That was a waste of effort!”
Waste
© STM Quality Limited
STM Quality Limited
Wasted Time
Just imagine if we could
collect all the time together that we have wasted in the
past -How much time would that be?
© STM Quality Limited
STM Quality Limited
Wasted Money
Just imagine if we could collect all the money together that
we have wasted in the
past -How much
money would that be?
© STM Quality Limited
STM Quality Limited
Wasted Effort
Just imagine if we could
collect all the effort together that we have wasted in the
past -How much effort
would that be?
© STM Quality Limited
STM Quality Limited
The Problem With Waste
The problem with wasted time, money & effort is:
When it’s gone…
- it’s gone!
© STM Quality Limited
STM Quality Limited
Eliminating Waste
So what can we do to eliminate waste?
We first need to identify what is & is not waste, then we can look at ways of eliminating or at least reducing waste.
© STM Quality Limited
STM Quality Limited
Identifying Waste in the Workplace
Operational ActivityValue added OperationsAny process that changes the nature,
shape or characteristic of the product in line with customer requirements
e.g. Pressing, welding, heat treatment.
This is where we make a profit!
© STM Quality Limited
STM Quality Limited
Identifying Waste in the Workplace
Operational ActivityNon-Value added OperationsWork carried out which is necessary
under current conditions, but does not increase product value.
e.g. Inspection, tool change, maintenance.
This is where we make a loss!
© STM Quality Limited
STM Quality Limited
Value Added and Non-Value Added operations
The objective is to raise the ratio of Value added operations to non-value added operations and eliminate waste.
WASTE NON-VALUE ADDEDVALUE ADDED
OPERATOR TIME
VALUE ADDED
NON-VALUE ADDED
MORE TIME FOR OTHER ACTIVITIES
ELIMINATE
© STM Quality Limited
STM Quality Limited
7W – The Elimination of Waste
So, now we understand the difference in value added & non-value added operations, what are the benefits in eliminating all waste?
• Reduced costs• Greater Capacity• Bottlenecks are identified
© STM Quality Limited
STM Quality Limited
7W – 7 Types of Waste
1 Over-production
2 Inventory
3 Transportation
4 Process5 Idle Time6 Operator Motion
7 Bad Quality
© STM Quality Limited
STM Quality Limited
7W – 1. Over-production
Over-production
Producing more than is needed hides a multitude of problems. Excessive set-up times, machine faults, risk of producing obsolete stock.
© STM Quality Limited
STM Quality Limited
7W – 2. Inventory
Inventory
Carrying stock attracts cost & storage problems. Storage leads to stacking, racking, sophisticated computers, bar coding & automation, all for an activity that adds no value to the product.
© STM Quality Limited
STM Quality Limited
7W – 3. Transportation
Transportation
This may appear unnecessary but does add value. Large transport is easily identified but small transport such as manual labour may not be so noticeable. These can be improved by changes to the work environment.
© STM Quality Limited
STM Quality Limited
7W – 4. Process
Process
Adds cost but no value - e.g.trimming & moulding to a level that is beyond the required standard adds extra time that customers do not want to pay for.
© STM Quality Limited
STM Quality Limited
7W – 5. Idle Time
Idle Time
Typically, waiting for products & services from preceding operations, waiting for work from their previous set-up or waiting for cycles to finish, or meetings to start.
© STM Quality Limited
STM Quality Limited
7W – 6. Operator Motion
Operator Motion
Typically, single handed operations where both should be used, stretching unnecessarily or awkwardly and walking between things. All of these take time or use time poorly, none add value.
© STM Quality Limited
STM Quality Limited
7W – 7. Bad Quality
Bad Quality
Rejects are always produced by systems and procedures created by management. If operators fail it is because the process allowed them to fail through inadequate training or because the process was not capable in the first place.
© STM Quality Limited
STM Quality Limited
7W – The Elimination of Waste
So, now we understand the 7 wastes, we can:
• Produce only what is needed;• Carry only essential stock;• Use transportation more wisely;• Produce work to the standard required;• Plan our production processes;• Put our efforts to the best possible use;• Train to make quality work every time!
