Lean methodology defines 8 forms of waste:
- Under utilized skills
Movement of material, paper etc. that adds unnecessary time to the flow, increasing risk of being lost, placed in wrong location during transportation.
Packaging or finished goods inventory, requires extra storage space and handling, raw materials not being processed.
Unnecessary steps in the process, increasing risk of delivering product to customer, could’ve been combined with other steps.
Finished goods are ready before customer needs them, occupying resources and considered one of the worst losses.
Failures of upstream process, creating idle time in current step, causing issues with downstream process.
Excessive turning, lifting, walking – all unnecessary motions that increase process time.
Rework generated due to damaged packaging, bad date code or best before on finished goods, product that was put on hold due to quality issues, resulting in lost sales or hidden costs.
Under utilized skills waste
Shop floor talent that is not used properly, causing lower employee morale, drive and creativity.
Gemba Waste Walk Template
We just talked about 8 sources of waste. Would you like to identify these at your manufacturing facility? Use our template while walking all areas, observe and note so it can be analyzed and actioned later on.