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Waste Walk ~ Audit
Waste Walk ~ Audit
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3 MU

  1. 1. Muda, Mura & Muri Why elimination of the "3 mu" is at the heart of kaizen? Anand Subramaniam
  2. 2. “The greatest wastes are unused talents and untried ideas..” - Unknown Source 2
  3. 3. 3 MU Muri Muda Mura • Unevenness • Unreasonableness • Unusefulness • Shifts in demand • A process, system, • An activity within or delivery that or facility designed a process that lead to a service beyond the physical does not add or support capacities of value, from the process being employees / perspective of the sped up or slowed equipment customer down (unsteady) 3
  4. 4. Taiichi Ohno  The Father of Toyota Production System, JIT, and Lean Manufacturing  Identified the 7 types of Muda 4
  5. 5. What is Waste ? Waste is “anything other than the minimum amount of equipment, materials, parts, space, and worker’s time which are absolutely essential to add value to the product.” Shoichiro Toyoda President, Toyota 5
  6. 6. Why Look @ Waste Reduction 6
  7. 7. Waste - Root Causes WOMBAT = Waste of Money, Brains And Time Inflexibility Variability Redundancy Schedule Task 7
  8. 8. Waste Types Transport Motion Rework Overproducing Inventory Waste Types Overprocessing Intellect 8
  9. 9. Waste Types (Contd.)  Transport  Movement of product that does not add value  Inventory  Ties up capital, takes valuable space, requires moving, difficulty in finding material, obsolescence, losses due to damage  Reduces customer responsiveness and multiplies quality problems 9
  10. 10. Waste Types (Contd.)  Motion  Movement of people that does not add value  Waiting  Idle time created when material, information, people, or equipment is not ready  Under utilising talent  Under utilising employees’ potential (their creative ideas) 10
  11. 11. Waste Types (Contd.)  Over processing  Effort that adds no value from the customer’s viewpoint  Defect  Work that contains errors, rework, mistakes or lacks something necessary  Creating / correcting defects robs resources, “chokes” flow 11
  12. 12. Waste Types (Contd.)  Overproduction  Producing more than the customer needs right now  Consumes valuable resources not immediately needed  Hides other process problems (bad quality, poor scheduling, poor delivery)  Builds inventory not needed 12
  13. 13. Waste Hierarchy  By Reducing waste, we minimise the load on landfill and transport  By sorting our wastes, we make it easier to Reuse and Recycle 13
  14. 14. Lean Tool to remove Waste Input Waste Lean Tool Man  Motion  Standard Work  Walking  5 S’s  Waiting  3P (Product Preparation  Searching Process) Machine  Motion  3P  Setup/Change over  Setup Reduction  Breakdown  TPM Material  Inventory  Pull System Method  Batch production  Flow Production  Transportation  One Piece Flow 14
  15. 15. “It has been my observation that most people get ahead during the time that others waste.” - Henry Ford 15
  16. 16. Good Luck http://www.linkedin.com/in/anandsubramaniam 16

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