Japanese Kaizen expert Suichi Yoshida defines Kaizen as “Continuous improvement by employee involvement through elimination of MUDA from all processes.” While waste within processes is referred to as MUDA, the term can also mean “non value-added activities that the customer doesn’t pay for.” As the popular quote “7 Waste” were the main target to identify and to eliminate or reduce by the Kaizen Blitz activities.
- Over Production : Producing more than, or faster than, is needed
- Poor production planning or scheduling, imbalanced production line or management practices that encourage build-up of inventory.
- Processing : Non value-added man or machine processing
- Inadequate value analysis or unclear customer specifications
- Transportation : Unnecessary material/tools/WIP movement
- Poor layout; poor workplace 5S; imbalanced production line; complex materials/ WIP flow
- Waiting time : Workers or machines idle
- Line imbalance; material or manpower shortage or delay; poor onsite management
- Inventory : Excessive stock or process work in progress (WIP) or finish good stock,
- Over-production; imbalanced line
- Motion : unnecessary worker movement
- Unclear standard operating procedures (SOP) or work instruction (WI), poor lay-out and housekeeping (5S)
- Reject/Rework : Work conducted to repair or defective products
- Inadequate processes; lack of quality awareness or control.
Although Seven Waste provides the most popular waste categories waste definition, any activities that give no added value could be identified as waste / MUDA.
How to Identify Waste / MUDA from Production Floor
Identify waste/ MUDA from by visiting the production floor.