Elements of Waste Elements of Waste 2 7 Components of Waste 5S Understanding Six Sigma Selecting Projects Elements of Waste Six Sigma Fundamentals Wrap Up amp Action Items Definition of Lean ID: 595904
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Slide1
Define Phase
Elements of WasteSlide2
Elements of Waste
2
7 Components of Waste
5S
Understanding Six Sigma
Selecting Projects
Elements of Waste
Six Sigma Fundamentals
Wrap Up & Action ItemsSlide3
Definition of Lean
3
“
Lean Enterprise is based on the premise that anywhere work is being done, waste is being generated.
The Lean Enterprise seeks to organize its processes to the optimum level, through the continual focus on the identification and elimination of waste.
”
-- Barbara WheatSlide4
Lean – History
4Slide5
Lean Six Sigma
Lean Six Sigma combines the strengths of each system:
5
Lean
Guiding principles based operating system
Relentless elimination of all waste
Creation of process flow and demand pullResource optimizationSimple and visual
Strength: EfficiencySix Sigma
Focus on voice of the customerData and fact based decision makingVariation reduction to near perfection levels
Analytical and statistical rigorStrength: Effectiveness
An Extremely Powerful Combination!Slide6
Project Requirements for Lean
Perhaps one of the most criminal employee performance issues in today
’
s organizations is generated not by a desire to cheat one
’
s employer but rather by a lack of regard to waste. In every work environment there are multiple opportunities for reducing the non-value added activities that have (over time) become an ingrained part of the standard operating procedure.
These non-value added activities have become so ingrained in our process that they are no longer recognized for what they are, WASTE.waste (
v.) Anything other than the minimum amount of time, material, people, space, energy, etc needed to add value to the product or service you are providing.
The Japanese word for waste is muda.
6
Get that stuff outta here!Slide7
Seven Components of Waste
Muda is classified into seven components:
Overproduction
Correction (defects)
InventoryMotionOverprocessingConveyance
WaitingSometimes additional forms of muda are added:Under use of talent
Lack of safety7
Being Lean means eliminating waste.Slide8
Overproduction
Overproduction
is producing more than the next step needs or more than the customer buys.
It may be the worst form of waste because it contributes to all the others.
8
Examples are:
Preparing extra reports
Reports not acted upon or even read
Multiple copies in data storageOver-ordering materials
Duplication of effort/reports
Waste of Overproduction relates to the excessive accumulation of work-in-process (WIP) or finished goods inventory.Slide9
Correction
Correction
of defects is as obvious as it sounds.
9
Examples are:
Incorrect data entry
Paying the wrong vendor
Misspelled words in communicationsMaking bad product
Materials or labor discarded during production
Eliminate errors!!
Waste of Correction includes the waste of handling and fixing mistakes. This is common in both manufacturing and transactional settings.Slide10
Inventory
Inventory
is the liability of materials that are bought, invested in and not immediately sold or used.
10
Examples are:
Transactions not processed
Bigger
“in box” than
“out box”Over-ordering materials consumed in-house
Over-ordering raw materials – just in case
Waste of Inventory is identical to overproduction except that it refers to the waste of acquiring raw material before the exact moment that it is needed.Slide11
Motion
Motion
is the unnecessary movement of people and equipment.
This includes looking for things like documents or parts as well as movement that is straining.
11
Examples are:
Extra stepsExtra data entry
Having to look for something
Waste of Motion examines how people move to ensure that value is added.Slide12
Overprocessing
Overprocessing
is tasks, activities and materials that don
’
t add value.
Can be caused by poor product or tool design as well as from not understanding what the customer wants.
12
Examples are:Sign-offs
Reports that contain more information than the customer wants or needsCommunications, reports, emails, contracts, etc that contain more than the necessary points (briefer is better)
Voice mails that are too long
Waste of Overprocessing relates to over-processing anything that may not be adding value in the eyes of the customer.Slide13
Conveyance
Conveyance
is
the unnecessary movement of material and goods.
Steps in a process should be located close to each other so movement is minimized.
13
Examples are:Extra steps in the process
Distance traveledMoving paper from place to place
Waste of Conveyance is the movement of material.Slide14
Waiting
Waiting
is nonproductive time due to lack of material, people, or equipment
.
Can be due to slow or broken machines, material not arriving on time, etc.
14
Examples are:
Processing once each month instead of as the work comes in
Showing up on time for a meeting that starts late Delayed work due to lack of communication from another internal group
Waste of Waiting is the cost of an idle resource.Slide15
Exercise
Exercise
objective:
To identify waste that occurs in your processes.
Write an example of each type of Muda below:
Overproduction
___________________Correction ___________________
Inventory ___________________
Motion ___________________Overprocessing
___________________Conveyance
___________________Waiting
___________________
15Slide16
5S – The Basics
5S is
a process designed to organize the workplace, keep it neat and clean, maintain standardized conditions and instill the discipline required to enable each individual to achieve and maintain a world class work environment.
Seiri - Put things in order
Seiton - Proper Arrangement
Seiso – Clean
Seiketsu – Purity
Shitsuke - Commitment16
5SSlide17
English Translation
There have been many attempts to force five English
“
S
”
words to maintain the original intent of 5S from Japanese. Listed below are typical English words used to translate: 1. Sort (Seiri)
2. Straighten or Systematically Arrange (Seiton)3. Shine or Spic and Span (Seiso)
4. Standardize (Seiketsu)5. Sustain or Self-Discipline (Shitsuke)
175 S
Sort
Identify necessary items and remove unnecessary ones, use time management.
Shine
Visual sweep of areas, eliminate dirt, dust and scrap. Make workplace shine.
Place things in such a way that they can be easily reached whenever they are needed.
Straighten
Make 5S strong in habit. Make problems appear and solve them.
Self-Discipline
Standardize
Work to standards, maintain standards, wear safety equipment.Slide18
Exercise
Exercise
objective:
To identify elements of 5S in your workplace.
Write an example for each of the 5S
’s below:
Sort
____________________Straighten ____________________
Shine ____________________
Standardize ____________________
Self-Discipline
____________________
18Slide19
Summary
At this point, you should be able to:
Identify and describe the 7 Elements of Waste
Describe 5S
Provide examples of how Lean Principles can affect your area
19Slide20
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’
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