1. Lean Methodology Topic - Muda-Mura-Muri.pptx

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1. Muda, Mura, Muri Discover how eliminating waste, variability, and overburdening lead to increased efficiency and quality in any workplace. by Munendra Sharma

2. Introduction What is Muda? The Japanese term for waste, Muda identifies all non-value adding and unnecessary tasks in processes. What is Mura? Refers to variation, overburdening, unevenness, and inconsistency in processes that hinder productivity and predictability. What is Muri? The Japanese term for overburdening, Muri occurs when tasks and processes demand too much from employees, equipment, or resources.

3. Types of Muda (1/2) Inventory Excessive amounts of inventory in a warehouse can lead to increased handling time and storage space. Overproduction Manufacturing more than is needed consumes more time and resources than required and can lead to storage and transportation waste.

4. Defects Re-work, scrap, or repair of defective products can cause production delays and additional costs. Waiting Employee idle time, production delays, and transportation interruptions are examples of non-value added waiting. Types of Muda (2/2)

5. Mura 1 Variation Improperly balanced workloads, machines, or equipment can lead to uneven productivity and efficiencies, hurting the bottom line. 2 Overburdening Overloading employees with more work than they can handle causes burnout, errors, and inefficiency. 3 Unevenness Fluctuations in product demand, supply chain disruptions, and unpredictable events can cause unevenness in the workplace.

6. MURI: Less is More Impact Excessive workloads, expectations, or complexity, leading to physical and mental strain, errors, and burnouts. Causes Multi-tasking, unclear priorities, lack of training, and poor organization, resulting in stress, confusion, and inefficiency. Solutions Reduce unnecessary tasks, simplify processes and systems, train and empower employees, and promote teamwork and well-being.

7. How to Eliminating Wastes ? Kanban Method Visual management system that tracks production and inventory levels to reduce waste. Value Stream Mapping Analysis tool that identifies sources of waste and helps optimize processes. Continuous Improvement Regularly reviewing and improving processes increases efficiency and reduces waste.

8. Case Study: Implementing Lean at Acme Industries Challenges Action Plan Results High inventory levels Implemented a Kanban system Inventory levels reduced by 50% Long lead times Conducted value stream mapping Lead times reduced by 80% Inconsistent quality Established a continuous improvement program Product defects reduced by 90%

9. From Theory to Practice: Successful Implementation 1 Toyota Production System Integrating LEAN principles into production processes, resulting in higher quality, lower costs, and faster lead times. 2 Zara Supply Chain Implementing Agile methodologies in fashion retail, enabling fast response to customer demand and reduced inventory. 3 Kaizen Event Facilitating cross-functional teamwork in short-term projects, leading to continuous improvement, cost savings, and employee engagement.

10. Practice Test : 1 1 2 3

11. Conclusion and Key Takeaways Eliminating MUDA, MURA, and MURI is a journey, not a destination. It requires a systematic and disciplined approach, continuous learning and experimentation, and a culture of teamwork and respect for people. Successful implementation can result in improved customer satisfaction, higher employee morale, and sustainable business growth.