Lean production is a methodology aimed at eliminating waste and improving efficiency in manufacturing and business processes. It is based on the idea that by identifying and eliminating non-value-adding activities, organizations can improve productivity, quality, and customer satisfaction. One of the key concepts in lean production is the identification and elimination of the “7 wastes,” which are activities that consume resources but do not add value to the product or service.
Key Facts
- Transportation: Unnecessary movement of materials, people, or equipment that results in wasted time and possible damage.
- Inventory: Excessive levels of inventory that take up valuable space, require resources to manage, and tie up capital.
- Motion: Unnecessary and inefficient movement of people or equipment that can cause harm, damage, or defects in the product.
- Waiting: Waste of time spent waiting for people, equipment, materials, or information to arrive, delaying the completion of work.
- Overproduction: Producing more than what is needed by the customer or the process, resulting in excess inventory and unnecessary expenses.
- Overprocessing: Performing more work than what is required by the customer, adding unnecessary steps or complexity to the process.
- Defects: Production errors or defects that lead to rework, scrap, or customer dissatisfaction.
The 7 Types of Wastes
The 7 types of wastes in lean production are:
Transportation
Unnecessary movement of materials, people, or equipment that results in wasted time and possible damage.
Inventory
Excessive levels of inventory that take up valuable space, require resources to manage, and tie up capital.
Motion
Unnecessary and inefficient movement of people or equipment that can cause harm, damage, or defects in the product.
Waiting
Waste of time spent waiting for people, equipment, materials, or information to arrive, delaying the completion of work.
Overproduction
Producing more than what is needed by the customer or the process, resulting in excess inventory and unnecessary expenses.
Overprocessing
Performing more work than what is required by the customer, adding unnecessary steps or complexity to the process.
Defects
Production errors or defects that lead to rework, scrap, or customer dissatisfaction.
Conclusion
The 7 types of wastes in lean production are a fundamental concept in identifying and eliminating non-value-adding activities in manufacturing and business processes. By understanding and addressing these wastes, organizations can improve productivity, quality, and customer satisfaction, ultimately leading to increased profitability and competitiveness.
References
- “7 Wastes of Lean Production.” PTC, www.ptc.com/en/blogs/iiot/7-wastes-of-lean-production. Accessed 15 Feb. 2023.
- “7+1 Wastes of Lean Types [Full Guide].” Operations1, operations1.com/en/blog/7-wastes-of-lean-production-and-how-to-avoid-them. Accessed 15 Feb. 2023.
- “7 Common Sources of Waste in Your Organization and How to Eliminate Them.” iSixSigma, www.isixsigma.com/dictionary/7-wastes-of-lean/. Accessed 15 Feb. 2023.
FAQs
What are the 7 types of wastes in lean production?
The 7 types of wastes in lean production are:
- Transportation: Unnecessary movement of materials, people, or equipment.
- Inventory: Excessive levels of inventory that take up space and tie up capital.
- Motion: Unnecessary and inefficient movement of people or equipment.
- Waiting: Waste of time spent waiting for people, equipment, materials, or information.
- Overproduction: Producing more than what is needed by the customer or the process.
- Overprocessing: Performing more work than what is required by the customer.
- Defects: Production errors or defects that lead to rework, scrap, or customer dissatisfaction.
Why is it important to identify and eliminate waste in lean production?
Identifying and eliminating waste in lean production is important because it helps organizations:
- Improve productivity and efficiency
- Reduce costs
- Improve quality
- Increase customer satisfaction
- Become more competitive
How can organizations identify waste in their processes?
Organizations can identify waste in their processes by:
- Observing and analyzing their processes
- Identifying activities that do not add value to the product or service
- Using lean tools and techniques, such as value stream mapping and spaghetti diagrams
What are some examples of waste in lean production?
Examples of waste in lean production include:
- Unnecessary movement of materials between workstations
- Excessive inventory levels
- Unnecessary setup and changeover times
- Waiting for materials, equipment, or information
- Producing more than what is needed by the customer
- Performing unnecessary inspections or tests
- Producing defective products
How can organizations eliminate waste in their processes?
Organizations can eliminate waste in their processes by:
- Redesigning their processes to eliminate non-value-adding activities
- Improving communication and coordination between departments
- Implementing lean tools and techniques, such as 5S, kanban, and single-piece flow
- Empowering employees to identify and eliminate waste
What are the benefits of eliminating waste in lean production?
The benefits of eliminating waste in lean production include:
- Increased productivity and efficiency
- Reduced costs
- Improved quality
- Increased customer satisfaction
- Improved competitiveness
How can organizations sustain their lean gains and prevent waste from creeping back into their processes?
Organizations can sustain their lean gains and prevent waste from creeping back into their processes by:
- Continuously monitoring their processes for waste
- Encouraging employees to continuously identify and eliminate waste
- Implementing a culture of continuous improvement
How can lean production principles be applied to non-manufacturing industries?
Lean production principles can be applied to non-manufacturing industries by:
- Identifying and eliminating non-value-adding activities in processes
- Improving communication and coordination between departments
- Empowering employees to identify and eliminate waste
- Implementing lean tools and techniques, such as 5S, kanban, and single-piece flow