In any business, the greatest enemy of profitability is
One of the most easily recognizable wastes in lean manufacturing is the production of Defects. Examples of Defects in manufacturing include waste such as scrap parts, products that require
When products do not conform to a customer’s requirements, the products must be repaired or remanufactured to satisfy the customer’s needs. If the customer’s requirements are not clear, more work may be performed during the creation of the product
Of all the 8 wastes in manufacturing, Overproduction has, by far, the most negative impact on success. Overproduction occurs any time more parts or products are produced than the customer is willing to purchase. Like the production of Defects and subsequent Excess Processing, Overproduction can also lead to the generation of additional lean manufacturing wastes such as Waiting, Inventory, and Motion, consuming vast amounts of time and resources.
Waiting is a reference to inaction that adds cost to a product being produced for a customer. This occurs because overhead costs continue to increase during the time the product waits to be transformed. When product waits, no value is being produced but the cost of overhead operations continues to grow, which strips potential profit from the sale. Waiting not only destroys material and information flow, but also generates excess Inventory.
Inventory is a manufacturing waste because it is
Moving product costs money, which is why Transportation is classified as a manufacturing waste category. Unless value-added transformation is performed to the product or material during transport, the Transportation of a product or material is wasteful activity. Great amounts of resources and time are consumed moving material while no value is being added to sell to the customer. Transportation leads to increased Motion lean waste because resources are required to move without generating value.
When Motion occurs,
The only lean manufacturing waste that is not manufacturing-process specific, but rather manufacturing management related, is Non-Utilized Talent. This type of manufacturing waste occurs when management in a manufacturing environment fails to ensure that all of their potential employee
Eliminating the 8 wastes of lean manufacturing is much easier when the production process is completely visible. MachineMetrics offers that transparency, allowing employees to engage with the actionable data in real-time. Manufacturers must understand what the customer is willing to pay for, then apply Lean Manufacturing to systematically eliminate the 8 wastes within production processes in order to maximize profitability.