7种浪费

SevenTypesofWasteOver-productionWaittimeTransportationProcessingInventoryMotionDefects7WastesOver-productionWasteDefinitionProducingmorethanneededProducingfasterthanneeded7WastesOver-productionWasteCharacteristics:•InventoryStockpiles•Extraequipment/oversizedequipment•UnbalancedMaterialFlow•ExtraPartStorageracks•ExtraManpower•BatchProcessing•ComplexInventoryManagement•ExcessiveCapacity/Investment•AdditionalFloorSpace/OutsideStorage•HiddenProblems•ExcessiveObsolescence•LargeLotSizes•BuildingAhead7WastesCauses:•IncapableProcesses•JustinCaseRewardSystem•LackofCommunication•LocalOptimization•AutomationintheWrongPlaces•CostAccountingPractices•LowUptimes•LackofStable/ConsitentSchedulesOver-productionWaste7WastesWaitingTimeWasteDefinitionIdleTimeThatisProducedWhenTwoDependantVariablesarenotFullySynchronized.•ManWaitTime•MachineWaitTime7WastesCharacteristics:•ManWaitingforMachine•Machine/MaterialsWaitingforMan•UnbalancedOperations(Work)•LackofOperatorConcernforEquipmentBreakdowns•UnplannedEquipmentDowntimeWaitingTimeWaste7WastesWaitingTimeWasteCauses:•InconsistentWorkMethods•LongMachineChangeOverTime•LowMan/MachineEffectiveness•LackofProperEquipment/Materials7WastesTransportationWasteDefinitionAnyMaterialMovementThatDoesNotDirectlySupportaLeanManufacturingSystem7WastesTransportationWasteCharacteristics:•Extracarts,forklifts,dollies•MultipleStorageLocations•ExtraMaterialRacks•ComplexInventoryManagement•ExtraFacilitySpace•IncorrectInventoryCounts•DamagedMaterial7WastesTransportationWasteCauses:•LargeLotProcessing•UnleveledSchedules•Lackof5S’s•LackofVisualControls•ImproperFacilityLayout•LargeBuffersandInProcessKanbans7WastesProcessingWasteDefinitionEffortWhichAddsNoValueToaProductorService.EnhancementswhichareTransparenttoTheCustomersorWorkWhichCouldBeCombinedwithAnotherProcess.7WastesCharacteristics:•ProcessBottlenecks•LackofClearCustomerSpecifications•EndlessRefinement•RedundantApprovals•ExtraCopies/ExcessiveInformationProcessingWaste7WastesCauses:•EngineeringChangesWithoutProcessingChanges•DecisionMakingatInappropriateLevels•InefficientPoliciesandProcedures•LackofCustomerInputConcerningRequirementsProcessingWaste7WastesInventoryWasteDefinitionAnySupplyinExcessofProcessRequirementsNecessarytoProduceGoodsorServicesJustinTime.7WastesInventoryWasteCharacteristics:•ExtraSpaceonReceivingDocks•MaterialBetweenProcesses•StagnatedMaterialFlow•LIFOinsteadofFIFO•ExtensiveReworkWhenProblemsSurface•LongLeadTimeforEngineeringChanges•AdditionalMaterialHandlingResources(Men,Equipment,Racks,StorageSpace)7WastesInventoryWasteCauses:•IncapableProcesses•UncontrolledBottleneckProcesses•IncapableSuppliers•LongChangeOverTimes•ManagementDecisions•LocalOptimization•InaccurateForcastingSystemsWaitTimeDefectsProcessOverProductionInventoryLevel7WastesMotionWasteDefinitionAnyMovementofPeopleWhichDoesNotContributeAddedValueToTheProductorService7WastesMotionWasteCharacteristics:•LookingforTools•ExcessiveReachingorBending•MaterialTooFarApart(WalkTime)•EquipmentforMovingParts•Extra“Busy”MovementsWhileWaiting7WastesMotionWasteCauses:•Equipment,Office&PlantLayout•Lackof5S’s•LackofVisualControls•InconsistentWorkMethods(StandardizedWork)•LargeBatchSizes7WastesReworkorCorrectionWasteDefinitionRepairofaProductorServiceToFulfillCustomerrequirements7WastesReworkorCorrectionWasteCharacteristics:•ExtraFloorSpace/Tools/Equipment•ExtraManpowerToInspect/Rework/Repair•StockpilingInventory•ComplexMaterialFlow•QuestionableQuality•MissedShipments/Deliveries•LowerProfitsDueToScrap•ReactiveOrganization7WastesReworkorCorrectionWasteCauses:•IncapableProcesses•ExcessiveVariation•IncapableSuppliers•ManagementDecisions•InsufficientTraining•InadequateTools/Equipment•PoorLayouts/UnnecessaryHandling•HighInventoryLevels7WastesSevenTypesofWaste7Wastes