APS Deployment Handbook

Wastes hunting
Author
Date
Version

R. DAVID
January 2011
01

Table of Contents
What
Tool Definition
Management
messages

WASTES HUNTING Definition

Quiz
What is waste?
Economical stakes
The 7th wastes

How
Tool
implementation

Excess processing
Waiting
Useless motion
Non quality
Inventory
Transport
Overproduction

WASTES HUNTING Implementation

Template
Observation: step to follow
Examples
Actions plan
Do it regularly
Reminder

Wastes hunting definition

Quiz

Repairing your car at the garage: 20/h

A technician welcomes you, and notes the time.
He goes to get the car in the car park (2 minutes).
The hydraulic lift is occupied, he brings down the previous
vehicle, but cannot find the keys
After 6 minutes, your car is in position.
He goes to get the tools that he needs (2 minutes) and
removes the part (5 minutes).
He goes to the warehouse to get the replacement part, but the
warehouse clerk is not there
After 8 minutes the warehouse clerk is back, and gives him the
part.
The mechanic tries to assemble the part, but the reference is
incorrect (2 minutes)
Her returns 5 minutes later with another part and mounts it (5
minutes).
He notes the time that he took to complete the work and gives
you theDo
bill!you agree with this bill?

NO
NO

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Wastes hunting definition

Economical stakes

Any activity that, from the

customers point
of view, does not add value to the
product or
the service.

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Wastes hunting definition

What is waste?

To deliver our customers what they want, when

they want it, we perform many activities in our
value stream that do not add value to the customer
we call this waste
Waste
Waste

Value

Value Stream

Waste
Waste
90% of our process is wastes and 10% is added value
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-5

Customer

Wastes hunting definition

Economical stakes

SALES
COSTS
COSTS

MARGIN

WASTE

WASTE

MARGIN

Waste hunting

COSTS

WASTE

MARGIN

Wastes elimination increases our added

value and is last but not least cost
reduction!!
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Wastes hunting definition

The 7th wastes

OUR PROCESSE IS MADE of STREAM of OPERATIONS

ADDED VALUE

and

WASTES

HOW CAN YOU SEE WASTES

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Wastes hunting definition

The 7th wastes

Traditionally we tend to focus on waste in operations:

In Between Operations

In Between Operations

In Between Operations

Operation

Operation

Operation

But there is far more potential in between

operations: the value stream perspective!
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Wastes hunting definition

The 7th wastes

WAITING

USELESS MOTIONS

EXCESS
PROCESSING

Wastes within the operations

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Wastes hunting definition

The 7th wastes

INVENTORY

NON QUALITY
TRANSPORT

Wastes within the flow

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Wastes hunting definition

The 7th wastes

OVERPRODUCTION

Wastes by non respect of the customer

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demand

Wastes hunting definition

The 7th wastes

WAITING

USELESS MOTIONS

EXCESS
PROCESSING

OVERPRODUCTION

INVENTORY

NON QUALITY
TRANSPORT

OVERPRODUCTION:
MOTHER
WICH WASTE
YOU HAVE TO FOCUS ONThe
FIRST????
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WASTES

of

Wastes hunting definition

The 7th wastes

Waste within operations:

EXCESS PROCESSING
WAITING

Watch the operations

USELESS MOTIONS
Waste within the flow:
NON QUALITY
TRANSPORT
INVENTORIES

but more importantly

in between!

Waste coming from the non-respect of the customer demand:

OVERPRODUCTION

Do not forget Overproduction: the mother

of all wastes!
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Wastes hunting definition

The 7th wastes

Why overproduction is the mother of waste?

By doing overproduction, you will create :
Transport
Uselessmotion
Non quality
. all the mudas..
So, keep in mind that, at first KILL the mother of muda!!!!

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Wastes hunting definition

Excess processing

Operations and processes not necessary from the

viewpoint of the customer

Causes
Product design and Process design not optimized
Equipment invested with the double of capacity level required
Added operations ( cleaning, washing, ...)
Work instructions not standardized

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Wastes hunting definition

Excess processing

Do not use a steamroller to squash a fly!

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Wastes hunting definition

Waiting

Machines, tools and people waiting for work and/or not being
used

Idle Operator

Wait

Watch

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Wastes hunting definition

Waiting

Machines, tools and people waiting for work and/or not being
used
Causes :
Lack of components,
Start of production waiting from quality decision,
Stoppages and micro stoppages,
Unbalancing lines or process,
Change over

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Wastes hunting definition

Waiting

Waiting is doing nothing

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Wastes hunting definition

Useless motion

Unnecessary, excess or movements by operators or tools

Walking

Lifting

Positioning

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Splitting / Dividing

Turning

Aiming

Searching

Pulling or Pushing

Wastes hunting definition

Useless motion

Unnecessary, excess or movements by operators or tools

Causes
Difficult to access: components, jigs, fixtures
No 5S
Packaging not adapted
Weak Ergonomics
Technical motion

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Wastes hunting definition

Useless motion

Avoid useless motions !

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Wastes hunting definition

Non quality

Products, parts and document that contain defects and/or

errors,
or operations needed to check the quality compliance

Inspect

Dis-assemble
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Re-work

Measure

Count

Adjust
-

Wastes hunting definition

Non quality

Products, parts and document that contain defects and/or

errors,
or operations needed to check the quality compliance
Causes
Process:
Capability not at the level required
No poka yoke
No Stoppage in case of defect

Administrative:
Instruction not clear
Obsolete instructions
Too late reaction

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Wastes hunting definition

Non quality

DO not accept rework and scrap

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Wastes hunting definition

Transport

Handling of a product, a resource (human, material.. ) or a

service.

Re-organize
Re-pack
Consolidate

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Filling
Re-constitute

Transport

Wastes hunting definition

Transport

Handling of a product, a resource (human, material.. ) or a

service.
Causes:
Complicated Flows,
Distance between workstations and areas,
Routes/Loop non organized,
Repetitive unloading and loading ,

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Wastes hunting definition

Transport

Transport is not Transform!

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Wastes hunting definition

Inventory

Goods and/or documents that are being retained for any

reason
inside or outside the Unit

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Wastes hunting definition

Inventory

Goods and/or documents that are being retained for any

reason
inside or outside the Unit
Causes :
Difference in quantity between the customer need and the
supplier
production
Supplier cycle time <> Customer cycle time
Customer demand not known
Bad accuracy of suppliers deliveries
Suppliers deliveries frequency not high enough
No decision to stop the production
High batch size
Process parameters not under control
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Wastes hunting definition

Inventory

Inventory hides the problems !

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Wastes hunting definition

Overproduction

Non-respect of customer demand: making unnecessary

products,
Supplier
Customer
too many, too early

Cycle time <>Takt time

Accumulating
a batch

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Producing
too much

Wastes hunting definition

Overproduction

Non-respect of customer demand: making unnecessary

products,
too many, too early
Causes :
Decide to produce more than the customer demand
Produce based on prevision
Produce faster than Takt Time
Production not smoothed
Batch size

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Wastes hunting definition

Overproduction

Overproduction the mother of wastes

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Wastes hunting definition

Template for listing Wastes

Do a 30 mn observation in an area
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Wastes hunting implementation

Observation: Steps to follow

Select an area
Observe the operations and around the operations
(within the flow)
Observe during 15 mns without writing anything
Fill the tracking sheet following the column corresponding
to the typology of waste
Put the description of the waste
Put the data corresponding to the waste you identified (Time, quantity)

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Wastes hunting implementation

Examples

Subassemblies stock

19 parts

In addition, take into consideration the

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surface

Wastes hunting implementation

Examples

Components bin
handling between supply
rack and workstation

30 seconds

In addition, take in consideration

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distance

Wastes hunting implementation

Build your action plan

The action sheet (Template APS-19-TP2)

When does it need to
be done?

What is your
organizational entity?

When was it actually

done?

Indicate the team or

area/zone

Put the date that

you wrote down the
action

Describe the issue or

need
Describe the action you
have to take to eradicate
the issue or answer the
need

Write down any notes made during

check activity

Who is responsible
for the action?
Track progress (action planned,
done, checked/verified and
possibly acted upon poor quality or
lateness of the action)

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Wastes hunting implementation

Do it continuously

Do the 30 min observation on monthly basis, fill your tracking

sheet and use it to build your continuous improvement
action plan
Excess

Stock

processing

Non quality

30 min
Waiting

Useless
motion

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Wastes hunting implementation

Reminder

Muda Hunting
is kaizen
activity !!
KAIZEN

STANDARDIZED
WORK

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PROGRESS

Wastes hunting implementation

Conclusion

NON-QUALITY

OVER-

PRODUCTION

(Inspection/Rework
Repair/Scrap)

WAITING

EXCESS

TRANSPORTATION

INVENTORY

MOVING

PROCESSIN
G

(People/
Handling)

Its NOW TIME to eliminate Wastes!

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