Tuesday, April 10, 2012

Tim Woods - 7 + 1 Wastes (Taken from Toyota Way Fieldbook)

Here is some more information in regards to the seven plus one wastes often discussed around Lean Six Sigma.  To find out how we can help you eliminate these from your business through a cost neutral solution while creating the bottom line benefits for your organisation send me an email at or visit our web site

With offices in Melbourne, Sydney, Perth, Adelaide & Brisbane we can assist you with a national program.  You will get access to all our experts, MBA's and back belts to maximise the benefits to your business.  We do not teach but coach.  We actively get involved on the floor, rather than just classroom style presentations.  Everyone participating in our programs will gain a nationally recognised qualification as an added bonus.

Transportation or conveyance. Moving work in process (WIP) from place to place in a process, even if it is only a short distance. Or having to move materials, parts, or finished goods into or out of storage or between processes.

Inventory. Excess raw material, WIP, or finished goods causing longer lead times, obsolescence, damaged goods, transportation and storage costs, and delay. Also, extra inventory hides problems such as production imbalances, late deliveries from suppliers, defects, equipment downtime,
and long setup times.

Movement. Any motion employees have to perform during
the course of their work other than adding value to the part, such as reaching for, looking for, or stacking parts, tools, etc. Also, walking is waste.

Waiting (time on hand). Workers merely serving as watch persons for  an automated machine, or having to stand around waiting for the next processing step, tool, supply, part, etc., or just plain having no work because of no stock, lot processing  delays, equipment downtime, and capacity bottlenecks.

Overproduction. Producing items earlier or in greater quantities than needed by the customer. Producing earlier or more than is needed generates other wastes, such as overstaffing, storage, and transportation costs because of excess inventory. Inventory can be physical inventory or a queue of information.

Overprocessing or incorrect processing. Taking unneeded steps to process the parts. Inefficiently processing due to poor tool and product design, causing unnecessary motion and producing defects. Waste is generated when providing higher quality products than is necessary. At times extra “work” is done to fill excess time rather than spend it waiting.

Defects. Production of defective parts or correction. Repairing of rework, scrap, replacement production, and inspection means wasteful handling, time, and effort.

Skill under utilised Losing time, ideas, skills, improvements,
and learning opportunities by not engaging or listening to your employees.