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seven deadly wastes in a production company

Updated on December 8, 2011

Identifying waste on the shopfloor

In a factory:

· Value added – those activities that change raw materials into value for customers;

· Waste – any activity that adds cost or time but not add value.

! - Waste gets built into a process because we find solutions to conditions and then forget to change the solution when the conditions change. It is important to ask why, over and over again, about everything we do. Only in this way will waste fail to take root.

Types of waste

1. The 3 MUs – capacity=load:

· MUDA (waste) – capacity>load

· MURA (inconsistency or variation) – sometimes capacity>load or load>capacity

· MURI (irrationality) – load>capacity.

Goal – a balance between capacity and load by eliminating non-value added activities troughout the production process.

2. The 5M+Q+S

Focus on the areas where waste may occur:

5M – man, material, machine, method, and management;

Q – quality;

S – safety.

3. The flow of goods in production

Four things are going on in a production flow:

Retention adds cost without adding value. (inventory, WIP – work in progress) -

Conveyance refers to transporting goods without adding value. (movement between retention points = conveyance, movement between retention point and process = material handling). -

Processing means adding value. -

Inspection identifies and eliminates defects from the production flow.(defects) -

Waste's types


The waste of – parts, bolds, welds, functions, storage and handling


Waste in disaster prevention methods, fixing defects.

(“Safety first” requires removing all waste that can lead to accidents and/or injuries.)


The waste of – large-lot production, inventory, conveyance, retention, non-stadardization, picking up an setting down work pieces


The waste of – making defective goods, fixing defects, errors, insoection, quality control


The waste of – materials, meetings, management control, communications, vouchers


The waste of - large machines, general purpose machines, conveyors, machine with wasteful movements, breakdowns, machine handling

1. Seven deadly waste

· Overproduction

· Inventory

· Conveyance

· Defects

· Processing waste

· Operation waste

· Idle time

How to discover waste

1. Use “back door” method. If you can’t see waste, find the value-added work. Everything else is waste!

2. Bring latent waste to the surface by implementing one-piece flow in the current, unimproved conditions.

3. Analyze current conditions using arrow diagrams, summary charts of flow analysis, operations analysis table, standard combination charts, and waste-finding checklists.

How to remove waste

1. Adopt an attitude that supports changing the way things have always been done.

2. Examine the four majore source of waste: retention, conveyance, processing, and inspection.

3. Eliminate unnecessary motion in machines.

4. Establish the optimum combination of people, machines, and materials.

How to prevent waste

1. Standardize

2. Use visual and auditory controls.(red-tagging 5S, signboards)

3. Ask “why” five times, and then ask “how”.

4. Keep improving your waste identification and eliminating efforts.

Waste-finding checklists

Magnitude of waste

0 …No waste found

1 …Very little waste

2 …Some waste

3 …A lot of waste


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