Monday 17 December 2018

How to reduce 7 Waste to increase productivity

7 Waste

The 7 waste of Lean Manufacturing explained in detail. Full descriptions of the 7 wastes including Muda, Mura and Muri. One of the factors that have to be fought in improving work productivity in industry is the large number of waste that is often not realize by most of its industry peers.

Eliminate wastage is one of the things that should be of particular concern. The waste in question covers everything excessive activities that have no add value (value add) in the live work activities.

7 Waste or Waste 7 in the language of Japan known for its young. Which was first introduced Ono as part of the concept of the TOYOTA PRODUCTION SYSTEM. as part of the approach increasing productivity cost savings-orient then the method of removal of Waste (Muda) must be taught. To every Member of the Organization as an absolute prerequisite.

In the lean manufacturing contexts emphasizing us to understand that every activity certainly consists of two parts, namely a value-added activity (add value) and activities that do not add value ( non-added value).

Excess Production (Over Production).

What is mean here is the creation of products that are a lot more, better and faster than early. So it tends to have an impact on the excess amount of preparation is require. Excess products are made a step towards a risk of requesting speculation against the high cost of production.

The waste associate with excessive production include:

  • Raw materials and preparation that much (overdone).

  • The addition of the area of storage and handling.

  • Investment capital not need concerning machines

  • and other equipment.

  • Increase product.

  • The addition of overhead.

  • Excessive labor Needs.

  • Confusing the determination of priorities in the process of production.


The transfer of products from the process of impact on the value of the mileage in the process of handling overload / results of products as well as removal of materials / raw materials require.

Although important, transportation does not add any value to the product. It is therefore define as a waste and should be eliminate.

Waste generate due to transport is:

  • Material damage in the process of transportation from one place to another.

  • Lost time in the process of transportation.

  • Loss of material.

  • Error material move.

  • The place of storage is require for material that is being wait for

  • to be move.

  • Chaos in the area of the workplace


Is the motion or movement is any movement of the machine or humans that are not required. For example, move it materials/goods from one place to another higher or that much because the layout placement materials/items are not effective.

In the process of the movement of the work must be move it the aspect of ergonomics such as when walking, bending lifting, reaching, stretch. The aspect of ergonomics in working with highly influential factor in health, safety and security for employees of the company.

Wastage cause by unnecessary movement:

  • Excessive weight and movement would potentially lead to injury.

  • Waste of time due to the work station layout was ineffective, so the movement of the flow of materials, parts, products and equipment that is not effective.

  • Lost time due to movement.

  • Lost time injury and cause the displacement of heavy items manually perform repeatedly.

  • The Assembly process on a regular basis that is not coordinate well in a team work so that will result in decrease productivity and completes on schedule.

Waiting (waiting)

The waiting time or idle cause by raw materials, materials/parts, information, people, equipment and systems. Which are not prepare according to plan. Each part/material goods are not moving or not process then a waste because waiting to happen.

Wastage incurred due to wait:

  • Increased lead time unused tools and tools that are idle.

  • The occurrence of bottleneck process

  • Low input production downstream of produce's.

  • Workforce Utilization & tools in the production process is not optimal

Process (over process):

Process or excessive movement or does not need to be done in work activities.

The waste that is generated due to excessive process:

  • The incidence of damaged goods and lost time due to unfavorable draft or machining process ineffective.

  • The goods are damaged or reworked by not having a specification is not clear.

  • The existence of additional storage and handling work item that is a "work-in-process".

  • Rework due to change orders after production began.

  • Use of the equipment require Extra lead time and excessive energy consumption.

  • Productivity decreased.


Excess material, part, stuff that is a WIP and products not required by the customer.

Excess mains tend to cause the issue a complicated issue in the factory which should be identified and properly controlled.

The possibilities that arise due to the caused by the preparation materials:

  • Loss of productivity the use of the storage area for supplies of materials.

  • Potentially causing errors against the product,

  • Capital who is unemploy.

  • Increase lead time process.

  • To raise the cost of care and handling supplies.

  • Potentially against damage inventory

  • Chaos search system

Damages/Defects (Defects) : work that is not in accordance with customer specifications (work process).

Wastage incurred because of damage include:

  • Reduce it raw materials, leading to a shortage of material that is needed.

  • Waste of time in the making or repair of damaged products.

  • Improving waiting times against the next process that affects the addition of costs and lead time.

  • Rework is a Job that is not useful because it can increase operational costs

  • Sorting product defects of the products received

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