LEAN- Type of Waste to Eliminate for LEAN Manufacturing.

LEAN : LEAN is a systematic method of elimination of waste.

There are 3 key word refered in Lean concept: MUDA, MURI & MURA.

MUDA: Waste

Anything that is non value adding is waste. There are typically 8 types of Waste.
Waste has negative effect on time, efforts, energy and money.

MURA: Unevenness

Unevenness results from an irregular production schedule, or fluctuating production volumes due to internal problems like down time, missing parts or defects.

MURI: Overburden

Muri is overburdening people or equipment beyond natural limits.

Overburdening people results in safety and quality problems. Overburdening equipment result in breakdowns and defects.

Customer buys value thro’ product or service for certain price.

Waste includes all that for which customer does not pay.

Value = Benefits / (Cost for VA + Cost for NVA )+ Profit

To improve value for customers,

1. Improve benefits thro’ improved product/service

2. Reduce price by reducing cost without affecting profits.

To reduce cost,

1. Eliminate non value adding (NVA) activities

2. Reduce resources required for value adding (VA) activities.

MUDA: Waste
There 8 type of Waste and it affects on business: In terms of productivity, time, durability, reliability, power, cost.

For optimization in process, it is very required to eliminate these wastes

Type of Waste	Examples	Reasons
Waiting	For material, Instruction, machine, tools, decision Machine waits for material	Line imbalance   Shortage  Batch Production  Breakdown Process constraints Inspection
Over Production	Producing what customer does not want Producing more than what customer wants	No customer focus, sellers mentality, Push Production focused performance incentives
Inventory	Raw material Stocks Work In Process Stocks Finished Goods Stocks	RM – Bulk Buying, Unreliable Supplies, High Lead Time WIP – Line Imbalance, Bottlenecks FG – Uneven demands, poor forecasting
Excessive motion	Operator’s movements viz. walk, bends, twists, sitting Manual material handling Manual adjustments	Poor Ergonomics Poor Work Station Designs Poor Std. Work Poor housekeeping
Transportation	Material Transport between stations, Additional trips, Partial Vehicle Loads	Large Distance between two stations, suppliers or plants Vehicles capacity not utilized Urgencies lead to extra transportation Batch Production needs transportation.
Over Processing	Duplications, Hierarchy of approvals High machining allowance Over designs, large safety margins	Improper product / process / system design
Defects/ Reworks	Scraps  Reworks   Repairs Regrade   Inspections	Poor inbuilt quality of  product  /process/service Lack of process control Incapable processes Excessive motion
Underutilized Human Potentials	Competent person allotted for unskilled jobs Incompetent persons Persons without required capacity to complete work Lack of authority Lack of creativity	Lack of mentoring Absence of training system Lack of challenges, motivation to perform better.

Tags:- Quality, QA/QC, Quality Problem,  Quality Improvement, Root Cause Analysis. CAPA. PDCA.Statistical Quality Control Kaizen. Six Sigma. Scatter Plot. Seven QC Tools. Kanban. FMEA. Bench-marking. 5'S. LEAN. OEE.Good Habits for Successful Engineers, The key to success, SWOT Analysis, Calibration