1 - Overproduction

• Overproduction = Making more of something than your customer asks/pays for

  • Overproduction is a type of waste that refers to the production of more than is needed, before it is needed, or faster than it can be consumed.

    • In the context of Lean, overproduction is considered a waste because it ties up resources (such as money, space, and time) and does not add value for the customer.

  • Overproduction can take many forms, such as producing more products than customers are currently demanding, producing products that are not of the right quality or specifications, or producing products that are not yet needed in the production process.

• Overall, reducing or eliminating overproduction is important in a Lean system because it reduces cost, enhances efficiency and frees up resources to focus on creating value for the customers.

2 - Transportation

• Transportation = Movement of products throughout a process

• Transportation is a type of waste that refers to the unnecessary movement of materials, parts, or products that do not add value for the customer.

  • This type of waste is considered a problem in a Lean context because it consumes time and resources, and increases the risk of errors or defects.

• Transportation waste can take many forms, such as moving materials, parts or products unnecessarily, or transporting them over long distances.

  • It may occur, for example, when materials or products are moved from one location to another without any reason, or when parts or materials are moved multiple times before they are used in the production process.

3 - Inventory

• Inventory = Storing excess products (AKA: Inventory)

  • Inventory takes up space that can otherwise be used for more production

• Inventory is a type of waste that refers to excess materials, parts, or products that are not being worked on or used.

  • Inventory is considered a waste in a Lean context because it ties up resources, such as money, space, and time, and does not add value for the customer.

• Inventory can take many forms, such as raw materials, work-in-progress, or finished goods.

  • It can be accumulated due to overproduction, delays in the production process, or changes in customer demand.

4 - Defects

• Defects = Anything that interrupts normal flow of a process

  • Internal Defects – Exists within a process or flow

  • External Defects – passed onto the customer

• Defects is a type of waste in the Lean framework, it refers to any errors or mistakes that require rework or waste resources.

  • This type of waste is considered a problem in a Lean context because it consumes time, resources, and money and does not add value for the customer.

• Defects can take many forms, such as errors in the production process, poor quality of materials, or mistakes in paperwork.

  • They can also occur due to other types of waste, such as overproduction or waiting, which can lead to materials or products being damaged or expired while they are being stored.

5 - Over-Processing

• Over-Processing = Putting more work into a product than what the customer is willing to pay for

• Over-processing is a type of waste that refers to any unnecessary or inefficient steps in a process that do not add value for the customer.

  • This type of waste is considered a problem in a Lean context because it consumes time, resources and money, and does not add value for the customer.

• Over-processing can take many forms, such as performing unnecessary testing or inspections, using unnecessary equipment or materials, or duplicating efforts that are already being performed by other processes.

  • It can also occur when there is a lack of standardization or when there is a lack of understanding of what the customer truly needs and wants.

6 - Motion

• Motion = Movement of people, which can include:

  • Walking, steps

  • Movement of arms, head, all body parts

• Excessive motion is bad for people, especially repetitive motion, and it can cause serious life-altering injuries:

  • Repetitive Motion Disorders (RMD’s) / Repetitive Strain Injuries (RSI’s), such as:

    • Carpal Tunnel, Bursitis, Tendonitis, Epicondylitis (“Tennis/Golfer’s Elbow”), Ganglion cyst, Tenosynovitis, “Trigger Finger”, etc.

• The cycle of waste is a visualization the "7/8 Wastes" of Lean, and the order in which waste multiplies & creates more waste

  • We do NOT recommend memorizing these wastes, but instead understanding how they related to one another, which will give you a much better grasp of the concepts

• Waste can start at any point in the cycle, but almost inevitably they lead to & create additional & different wastes

  • It is important to address waste when you see it, but if you can also identify the Root Cause of the waste (what waste/wastes started the cycle), and tackle that, you often solve more than one problem at a time

• These wastes are often interconnected and can lead to or exacerbate each other. For example:

  • • Overproduction can lead to excess products that need to be...

    • Transported to storage, also known as...

    • Inventory, where products can lead to being...

    • Defective if materials, parts, or products become damaged or expire while they are being stored, which requires...

    • Over-processing in the form of inspection paperwork, re-work, etc., which when finished needs to be...

    • Moved back into production, during which the whole time your customer is...

    • Waiting for the product, all of these wastes ultimately contributing to...

    • Wasted Human Potential