1.3 01 The Seven Forms of Wastes

What is one of the characteristics of overproduction waste?

• Making product behind schedule

• Producing exactly what the customer needs

• Having a well-balanced production process

• Reducing the risk of manufacturing ahead of schedule

What is a major cause of waiting waste in factories?

• Producing small batch sizes

• Poor balance of work

• Low inventory levels

• Efficient machinery monitoring

What can lead to excess transportation handling waste in factories?

• Excessive inventory

• Appropriate positions for raw materials

• Efficient factory layout

• Low inventory levels

What is a characteristic of high inventory waste?

• Small stocks of work in progress

• Quick discovery of quality problems

• Work areas cluttered with materials

• Less material handling and transportation

What is a characteristic of unnecessary motion waste?

• Less work related injuries

• Excessive time spent on set ups

• Better operator environment

• Efficient work environment

What is a common cause of over-processing waste?

• Adequate education/training/work instructions

• Product changes without process changes

• Balanced inventory level

• Deficient planned maintenance

What is a characteristic of defective units waste?

• Large containers for collecting reject parts

• High confidence in production schedules

• Low costs of rework and waste disposal

• Improved capacity and ability to meet production schedules

What is a cause of under-utilizing people waste?

• Efficient utilization of people's abilities

• High investment in training

• Low pay

• Low turnover strategy

What is a benefit of eliminating overproduction waste?

• Prevents 'manufacturing at risk' ahead of customer schedule

• Increases the real problems in manufacturing

• Increases operator boredom

• Reduces the risk of handling damage

What is a benefit of eliminating idle time waste?

• Better utilisation of operator time

• Increased operator boredom

• More traffic in gangways

• Increased risk of handling damage