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    Presentation 1 8 Wastes

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    029-SHREYA MANDHANA
    The document discusses the eight wastes of lean manufacturing: motion, defects, overproduction, waiting, non-utilized talent, transportation, inventory, and extra processing. It provides examples of each waste and potential countermeasures. It then discusses value stream mapping and presents an "as is" scenario with key metrics like lead time, value added time, and process cycle efficiency.

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    Presentation 1 8 Wastes

    Uploaded by

    029-SHREYA MANDHANA
    197 views16 pages
    The document discusses the eight wastes of lean manufacturing: motion, defects, overproduction, waiting, non-utilized talent, transportation, inventory, and extra processing. It provides examples of each waste and potential countermeasures. It then discusses value stream mapping and presents an "as is" scenario with key metrics like lead time, value added time, and process cycle efficiency.

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    The document discusses the eight wastes of lean manufacturing: motion, defects, overproduction, waiting, non-utilized talent, transportation, inventory, and extra processing. It provides examples of each waste and potential countermeasures. It then discusses value stream mapping and presents an "as is" scenario with key metrics like lead time, value added time, and process cycle efficiency.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    197 views16 pages

    Presentation 1 8 Wastes

    Uploaded by

    029-SHREYA MANDHANA
    The document discusses the eight wastes of lean manufacturing: motion, defects, overproduction, waiting, non-utilized talent, transportation, inventory, and extra processing. It provides examples of each waste and potential countermeasures. It then discusses value stream mapping and presents an "as is" scenario with key metrics like lead time, value added time, and process cycle efficiency.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 16

    Presentation 1

    8 WASTES
    World Class 8 wastes of lean manufacturing &
    Value Stream Mapping

    Manufacaturing
    Group 2
    023 SHREYASH KABADE
    029 SHREYA MANDHANA
    051 ARBAZ SHAIKH
    074 DARSHAN CHOPDEKAR
    097 JIDNAYASA MANDARE
    Waste
    • In Lean manufacturing, “waste” is
    any action that does not add value to
    the Product
    • waste is any unnecessary step in a
    manufacturing process that does not
    benefit the customer
    • the customer does not want to pay for
    it
    8 Wastes of Lean
    Motion
    • Motion not only includes raw materials
    but also people and equipment's motion Examples
    • It may also include excess physical • Poor workstation layout
    motion such as reaching, lifting and • Poor production planning
    bending • Poor process design
    • All unnecessary motion results in non-
    value-added time and increases cost.

    This waste can be caused by - Counter measures for this Defect -


    • Poor Shop floor Layout • 5s Work Management
    • Workstation Congestion • One Piece Flow
    Defect
    • Defects are when s
    products or
    Examples
    • Scrap produced by poorly maintained
    service deviate from what the fixtures.
    customer requires or the • Parts assembled with the incorrect
    specification. orientation.

    Defect waste can be caused by -


    Counter measures for avoiding Defect -
    • Poor Quality control
    • Poka Yoke
    • Lack of Standards
    • Root cause analysis
    • Unstrained workers
    Non utilized Talent
    • When management fails to Examples
    ensure that all their potential • Poor communication
    • Failure to involve people in
    employee talent is being
    workplace design and development
    utilized.
    • Lack of or inappropriate policies

    This waste can be caused by -


    • Lack of Motivation and Lost Counter measures for this Defect -
    creativity • Proper communication channel
    • Lack of Teamwork • Proper Training plan
    Over Production
    Examples
    • Farm Produce amid Pandemic
    • producing more than what you
    Covid 19
    need to supply your customer.
    • Creation of meals at restaurant
    • Triggers other wastes. that are not eaten or partially
    eaten
    Over Production waste can be caused by -
    Counter measures for avoiding Over Productio
    • Unclear Customer Need
    -
    • Poor applied automations
    • Just In Time
    • Accurate Forecasting
    Transportation
    • when you move resources (materials),
    Examples
    and the movement doesn’t add value
    • Purchase manager negotiating a
    to the product
    bigger batch size
    • Excessive movement of materials can
    • Sending unsold products from
    be costly to your business and cause
    the store back to the warehouse
    damage to quality.

    This waste can be caused by -


    • Poor plant Layout Counter measures for this Defect -
    • Misaligned Process Flow • Value Stream Mapping
    Waiting time
    Examples
    • Waiting can include people, • Unplanned downtime or Idle equipment
    material equipment (prior runs • Long or delayed set-up times
    not finished) or idle • Poor process communication
    • Lack of process control
    equipment (mechanical
    • Idle equipment
    downtime or excess
    changeover time).
    This waste can be caused by - Counter measures for this Defect -
    • Unplanned workload • Continuous one piece flow
    • Long setup time • Value stream Mapping
    • Poor process quality
    Extra Processing
    Examples
    • Extra processing is a sign of a
    • Not understanding your
    poorly designed process. This
    customers’ needs
    could be lack of communication,
    • Human error
    duplication of data, overlapping
    • Slow approval process or
    areas of authority and human error.
    excessive reporting

    This waste can be caused by - Counter measures for this Defect -


    • Overdesigned equipment • Process Reevaluation
    • Lack of Standards • Value Stream Mapping
    Inventory
    • Inventory is famously known as
    Impacts
    • Capital stuck in inventory
    necessary evil
    • Cost of capital
    • 3 types of inventory
    • Space / Extra Space
    • Obsolescence of inventory
    • Opportunity Cost
    This waste can be caused by -
    • Bullwhip effect
    • Long Setup times
    • Poor Monitory system
    Presentation 2
    VSM
    VSM "As is " Scenario

    lead time = 30.55 days

    value added time = 310 sec

    PCE= value added time / lead


    time
    = (310/2639520)*100
    = 0.01136 %

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