Why elimination of the "3 mu" is at the heart of kaizen?

1. Muda, Mura & Muri
Why elimination of the "3 mu" is at
the heart of kaizen?
Anand Subramaniam

2. “The greatest wastes are unused talents and
untried ideas..”
- Unknown Source
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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)
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4. Taiichi Ohno
 The Father of Toyota
Production System,
JIT, and Lean
Manufacturing
 Identified the 7 types
of Muda
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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
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6. Why Look @ Waste Reduction
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7. Waste - Root Causes
WOMBAT = Waste of Money, Brains And Time
Inflexibility Variability Redundancy
Schedule Task
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8. Waste Types
Transport
Motion Rework
Overproducing Inventory
Waste Types
Overprocessing
Intellect
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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
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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)
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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
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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
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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
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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
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15. “It has been my observation that most
people get ahead during the time that
others waste.”
- Henry Ford
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16. Good Luck
http://www.linkedin.com/in/anandsubramaniam
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