1. Waste Walk / Audit
“Structured process to eliminate waste
with the appropriate Lean Tools”
Anand Subramaniam

2. “Don't waste good iron for nails or good men
for soldiers.”
- Chinese Proverb
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3. Transport
Waste Causes Counter Measures
• Moving parts in and out • Safety • Kanban
of storage • Storage • Flow lines
• Moving material from one • Push production • Pull system
workstation to another • Over production • Value Stream
• Capital Expenditure • Functional layout • Supply chain
• Increases damage management
• Batch production
• Multiple staging
points
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4. Excess Inventory
Waste Causes Counter Measures
• Raw materials • Lack of flow • Build to order
• Finished goods • Long set-ups • Internal kanban
• Work in process • Long lead-times • External kanban
• Consumable supplies • Over production • Set-up reduction
• Purchased components • Paperwork in process • One-piece flow
• High levels of safety stock • Lack of ordering lines Supplier
procedure development
• Long queues in
service operations
• Large deposits of
material at each
operation
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5. Excess Motion
Waste Causes Counter Measures
• Non ergonomic moves • Unsafe • 5S
• Reaching for tools • Cycle time • One-piece flow
• Lifting boxes of parts • Inefficiency • Workstation
• Sorting through materials • Missing items design
• Searching for BOMS, • Unsafe work area • POUS
parts, tools, prints, work • Disorganised • Water Spider (one
instructions, etc. workplace who performs a
• Poor workstation wide range of tasks
design – stocks the line)
• 3P (Production
Preparation &
Process)
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6. Waiting
Waste Causes Counter Measures
• Waiting for parts • Lack of priority • TPM
• Waiting for prints • Work imbalance • Jidoka
• Waiting for machines • Push production • Office Kaizen
• Waiting for inspection • Order entry delays • Downstream pull
• Waiting for information • Centralised • In-process gauging
• Waiting for machine inspection • Takt time
repair • Lack of production
communication
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7. Overproduction
Waste Causes Counter Measures
• Producing more to avoid • Forecasting • TPM
set-ups • Long set-ups • Set-up reduction
• Producing product to • Poor Communication • Pull system
stock based on sales • “Just in case” for scheduling
forecasts breakdowns • Heijunka -level
• Batch process resulting in loading
extra output
• Working on the wrong
parts at the wrong time
• Making more parts than
your customer needs
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8. Overprocessing
Waste Causes Counter Measures
• Inspection • Push system • 3P
• Paperwork • VOC not understood • 5S
• Over-tight tolerances • Unnecessary approvals • Flow lines
• Multiple cleaning of parts • Redundant processes • Lean Design
• Awkward tool or part design • Delays between • Office Kaizen
• Consumes valuable processing • One-piece pull
resources • Opportunity for more
• Designs “thrown over the defects
wall” • Processing beyond
specification limits or
customer requirements
• Unnecessary record
retention
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9. Defects
Waste Causes Counter Measures
• Scrap • Process failure • 3P
• Defects • Mis-loaded part • Jidoka
• Rework • Batch process • Six Sigma
• Variation • Inspect-in quality • Poka Yoke
• Correction • Incapable machines • Built-in quality
• Field failure • One Piece Flow
• Missing parts
• Wrong parts from supplier
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10. Under Utilised Talent
Waste Causes Counter Measures
• Poor quality • Mistrust • Kaizen
• High turn over • Lack of goals • Job rotation
• High Absenteeism • Poor training • Cross training
• Poor job satisfaction • Poor communication • Empowerment
• Lack of • Problem Solving
empowerment • Idea
• No control over implementation
situations
• Lack of feedback on
ideas
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11. Waste Audit
How will we know we
Possible Cause Proposed Action
were successful?
Transportation
Excess Inventory
Excess Motion
Waiting
Overproduction
Overprocessing
Defects
Under Utilised Talent
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12. Waste Measures
 By numbers:
 Loads
 Contents
 By observation:
 Survey
 Photos (before and after)
 By impact:
 Problem solved (through Improvement Idea)
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13. Waste Removal – Improvement Ideas
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14. Follow-up Activities
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15. “Give a man a beer, waste an hour. Teach a
man to brew, and waste a lifetime!”
- Bill Owen
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16. Good Luck
http://www.linkedin.com/in/anandsubramaniam
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