7 Wastes

7 Wastes (MUDA) – Explanations and examples in simple way by - 5S BALAMURUGAN

1. -Sholavandan Balamurugan

2. The seven wastes are categories of unproductive manufacturing practices
identified by Taiichi Ohno, the father of the Toyota Production System.
The categories are an integral part of the TPS / Lean production.
Simply we can remember the Seven Wastes by using the below acronym.
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3.  Transportation
 Inventory
 Motion
 Waiting
 Over Production
 Over Processing
 Defects
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4. Unnecessary movement of people or parts between processes.
Moving a product between manufacturing processes adds no value, is
expensive and can cause damage or product deterioration.
Example :
Moving hospital patients from department to department
Sending overstocked inventory back to a warehouse or an outlet store location
In software, it may mean moving code from one server or repository to another
Transportation of products from one functional area to another
Transport Inventory Motion Waiting
Over
production
Over
processing
Defects
© Sholavandan BALAMURUGAN

5. Excess products / materials (raw material, work in progress) not being
processed.
It leads costs of storage and maintenance.
Example :
Excess production of promotional materials or printed forms
Produce or food that goes to waste in our kitchen
Kitchen gadgets that are accumulated and not used
Unused or rarely used equipment
Transport Inventory Motion Waiting
Over
production
Over
processing
Defects
© 5S BALAMURUGAN

6. Unnecessary movement of people, parts or machine within a process.
Example :
People searching for materials, tools or equipment
Handoffs in software development
Poorly structured or disorganized work spaces
Having to make too many clicks in a website or software to accomplish a small
task
Transport Inventory Motion Waiting
Over
production
Over
processing
Defects
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7. Parts or people waiting for processing to be completed.
Example :
Patients in waiting rooms
Waiting for responses from other departments
Manufacturing processes waiting for component delivery
Waiting for a flight that's been delayed due to maintenance being done wrong
Transport Inventory Motion Waiting
Over
production
Over
processing
Defects
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8. Manufacture of products in advance or in excess of demand wastes money,
time and space.
Example :
Production of components before the next stage in the process is ready to
receive them
Printing and filing of unnecessary documents
Creation of meals that are not eaten or partially eaten
Cars that sit unsold in a car dealer lot
Transport Inventory Motion Waiting
Over
production
Over
processing
Defects
© Sholavandan BALAMURUGAN

9. Processing that exceeds the level required to meet specification.
Example :
Entering the same data in more than one place on a form or in a
software application
Multiple approval levels for a small spending request
Ordering unnecessary tests for patients
Extra report information
Transport Inventory Motion Waiting
Over
production
Over
processing
Defects
© 5S BALAMURUGAN

10. Efforts caused by rework, scrap and incorrect information.
Example :
Scrap produced by poorly maintained fixtures
Parts assembled with the incorrect orientation
Incorrect components used due to incorrect, or missing instructions
Poorly made components that continued to be made as the employees
wanted to reach their performance bonus
Faulty parts that have reached the customer
Transport Inventory Motion Waiting
Over
production
Over
processing
Defects
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11. Some people have added an eighth waste to Ohno's original list. As a
result, the 8 wastes are commonly referred to as ‘TIMWOODS’.
The 8th waste is – Non-utilized Human Resources / Talent – The waste of not
using people to the best of their unique abilities.
Example :
Employees spend time on tasks that do not add value
Career development and planning is absent
People with advanced skills do routine work
Employee ideas for improvement are ignored
Transport Inventory Motion Waiting
Over
production
Over
processing
Skills
Defects Defects
© 5S BALAMURUGAN

12. 5S Tamil - Basic https://www.slideshare.net/BalaMurugan272/5s-tamil
Quality Circle
Tamil
(jutl;lk; jkpopy;)
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circle-tamil
Kaizen Tamil
(nfa;rd;)
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96728468
Workplace
Safety
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ce-safety-93453644
PDCA /
Deming Wheel
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tamil-119387518
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13. Thank You.
Sholavandan BALAMURUGAN
B.Sc(CS).,MBA.,M.A(IR).,M.Sc(Psy).,PHRM.,
9043365658 | [email protected]
https://www.linkedin.com/in/balamuruganm21/
Please feel free to contact me.. If you have any queries or comments…
7
Wastes