APS Waste Hunting DH 201101 01

AuthorDate

Version

APS Deployment Handbook

EHS Quality

Basic Principles

Management & Leadership

Industrial excellence

Wastes hunting

R. DAVIDJanuary 201101

What

Tool Definition

Management messages

How

Tool implementation

WASTES HUNTING Definition − Quiz− What is waste?− Economical stakes− The 7th wastes

• Excess processing• Waiting• Useless motion• Non quality• Inventory • Transport• Overproduction

WASTES HUNTING Implementation− Template− Observation: step to follow− Examples− Actions plan− Do it regularly− Reminder

Table of Contents

APS-Waste Hunting-DH-201102-01 - 3-

Do you agree with this bill?

Wastes hunting definitionQuiz

Repairing your car at the garage: 20€/h− A technician welcomes you, and notes the time.− He goes to get the car in the car park (2 minutes).− The hydraulic lift is occupied, he brings down the previous

vehicle, but cannot find the keys…− After 6 minutes, your car is in position.− He goes to get the tools that he needs (2 minutes) and

removes the part (5 minutes).− He goes to the warehouse to get the replacement part, but the

warehouse clerk is not there…− After 8 minutes the warehouse clerk is back, and gives him the

part.− The mechanic tries to assemble the part, but the reference is

incorrect (2 minutes) …− Her returns 5 minutes later with another part and mounts it (5

minutes).− He notes the time that he took to complete the work and gives

you the bill! NONO


Any activity that, from the customer’s point

of view, does not add value to the product or

the service.

Wastes hunting definitionEconomical stakes


To deliver our customers what they want, when they want it, we perform many activities in our value stream that do not add value to the customer – we call this waste

ValueValue Stream

Waste

Waste

Customer

Waste

Waste

90% of our process is wastes and 10% is added value

Wastes hunting definitionWhat is waste?


MARGIN

SALES

WASTE

COSTS

WASTE

Waste hunting

COSTS MARGIN

COSTS WASTE MARGIN

Wastes elimination increases our added value and is last but not least cost

reduction!!

Wastes hunting definitionEconomical stakes


OUR PROCESSE IS MADE of STREAM of OPERATIONS

ADDED VALUE and WASTES

HOW CAN YOU SEE WASTES

Wastes hunting definitionThe 7th wastes



Traditionally we tend to focus on waste in operations:

Operation

Operation

Operation

In Between Operations



But there is far more potential in between operations: the value stream perspective!


WAITING USELESS MOTIONS

EXCESS PROCESSING

Wastes within the operations



INVENTORY

TRANSPORT

NON QUALITY

Wastes within the flow



OVER-PRODUCTION

Wastes by non respect of the customer demand



OVER-PRODUCTION

WICH WASTE YOU HAVE TO FOCUS ON FIRST????

WAITING USELESS MOTIONS

EXCESS PROCESSING

INVENTORY

TRANSPORT

NON QUALITY

OVERPRODUCTION: The MOTHER of WASTES




Waste within operations:

− EXCESS PROCESSING

− WAITING

− USELESS MOTIONS

Waste within the flow:

− NON QUALITY

− TRANSPORT

− INVENTORIES

Waste coming from the non-respect of the customer demand:

− OVERPRODUCTION

Watch the operations…

…but more importantly……in between!

Do not forget Overproduction: the mother of all wastes!



Why overproduction is the mother of waste?

By doing overproduction, you will create :

Transport

Uselessmotion

Non quality

…. all the mudas…..

So, keep in mind that, at first KILL the mother of muda!!!!


Wastes hunting definitionExcess processing

Operations and processes not necessary from the viewpoint of the customer

Causes

− Product design and Process design not optimized

− Equipment invested with the double of capacity level required

− Added operations ( cleaning, washing, ...)

− Work instructions not standardized


Do not use a steamroller to squash a fly!

Wastes hunting definitionExcess processing


Wait

Watch

Idle Operator

Wastes hunting definitionWaiting

Machines, tools and people waiting for work and/or not being used



Machines, tools and people waiting for work and/or not being used

Causes :

• Lack of components,

• Start of production waiting from quality decision,

• Stoppages and micro stoppages,

• Unbalancing lines or process,

• Change over


Waiting is doing nothing



Walking Lifting TurningSplitting / Dividing

Positioning Searching Aiming Pulling or Pushing

Wastes hunting definitionUseless motion

Unnecessary, excess or movements by operators or tools



Unnecessary, excess or movements by operators or tools

Causes

− Difficult to access: components, jigs, fixtures

− No 5S

− Packaging not adapted

− Weak Ergonomics

− Technical motion


Avoid useless motions !



Inspect Re-work Measure

CountDis-assemble Adjust

Wastes hunting definitionNon quality

Products, parts and document that contain defects and/or errors, or operations needed to check the quality compliance



Products, parts and document that contain defects and/or errors, or operations needed to check the quality compliance

Causes

− Process:

• Capability not at the level required

• No poka yoke

• No Stoppage in case of defect

− Administrative:

• Instruction not clear

• Obsolete instructions

• Too late reaction


DO not accept rework and scrap



Consolidate

Re-pack

Re-constitute

Re-organize

Transport

Filling

Wastes hunting definitionTransport

Handling of a product, a resource (human, material.. ) or a service.



Handling of a product, a resource (human, material.. ) or a service.

Causes:

− Complicated Flows,

− Distance between workstations and areas,

− Routes/Loop non organized,

− Repetitive unloading and loading ,


Transport is not Transform!



Wastes hunting definitionInventory

Goods and/or documents that are being retained for any reason inside or outside the Unit



Goods and/or documents that are being retained for any reason inside or outside the Unit

Causes :

− Difference in quantity between the customer need and the supplier production

− Supplier cycle time <> Customer cycle time

− Customer demand not known

− Bad accuracy of suppliers deliveries

− Suppliers deliveries frequency not high enough

− No decision to stop the production

− High batch size

− Process parameters not under control


Inventory hides the problems !



Wastes hunting definitionOverproduction

Non-respect of customer demand: making unnecessary products, too many, too early

Accumulatinga batch Producing

too much

Supplier Customer

Cycle time <>Takt time



Non-respect of customer demand: making unnecessary products, too many, too early

Causes :

− Decide to produce more than the customer demand

− Produce based on prevision

− Produce faster than Takt Time

− Production not smoothed

− Batch size


Overproduction the mother of wastes



Do a 30 mn observation in an area

Wastes hunting definitionTemplate for listing Wastes

1 1 1 1 1 1 1

2 2 2 2 2 2 2

3 3 3 3 3 3 3

TotalTotal Total TotalTotal TotalTotal

Time

Time

Time Quantity Time

Time

Description

Time

Quantity

Description Description

TimeQuantity

Quantity

Quantity

Time

DescriptionDescription

Quantity

TimeQuantityQuantity

Description Description Description

Time

DescriptionDescription Description DescriptionDescription

Quantity

Description

Time Time

Description

Workplace

useless Motion Excess processing

Description Description DescriptionDescription

Non quality Over-production Waiting Transport Inventory

Date/ /

Author

Description

Area / LineTracking down wastes

Description

EHS Quality

Basic Principles




Wastes hunting implementationObservation: Steps to follow

− Select an area

− Observe the operations and around the operations (within the flow)

− Observe during 15 mns without writing anything

− Fill the tracking sheet following the column corresponding to the typology of waste

− Put the description of the waste

− Put the data corresponding to the waste you identified (Time, quantity)


1 1 1 1 1 1 1

2 2 2 2 2 2 2

3 3 3 3 3 3 3

Time

Description

Quantity


Time

Description

Time


DescriptionDescription

TimeQuantity

Unnecessary motion

Description

Area / LineTraking down wastesWaiting time Stock

Author

Subassemblies stock

19 parts

In addition, take into consideration the surface

Wastes hunting implementationExamples


Components bin handling between supply

rack and workstation

30 seconds

1 1 1 1 1 1 1

2 2 2 2 2 2 2

3 3 3 3 3 3 3

Time

Time

Time

Description

Time


Quantity


Description


Quantity

Traking down wastesTransport

Unnecessasry operations

Defect & rework

Description

In addition, take in consideration distance

Wastes hunting implementationExamples


Date N° Solution & Action Due Date Date done P D C A Status/commentsProblem & cause / Need & reason

Organization Team :

ACTION SHEET

Pilot

EHS Quality

Basic Principles



The action sheet (Template APS-19-TP2)

What is your organizational entity?

Put the date that you wrote down the

action

Describe the action you have to take to eradicate the issue or answer the

need

Write down any notes made during check activity

Track progress (action planned, done, checked/verified and

possibly acted upon poor quality or lateness of the action)

When was it actually done?

When does it need to be done?

Who is responsible for the action?

Describe the issue or need

Indicate the team or area/zone

Wastes hunting implementationBuild your action plan


Wastes hunting implementationDo it continuously

Do the 30 min observation on monthly basis, fill your tracking sheet and use it to build your continuous improvement

action plan

30 min

Stock

Useless

motion

Excess

processing

WaitingNon quality


KAIZEN

STANDARDIZED WORK

PROGRESS

Muda Hunting is kaizen activity !!

Wastes hunting implementationReminder


TTRANSPOR-

TATIONTTRANSPOR-

TATION

EEXCESS

PROCESSING

EEXCESS

PROCESSINGMMOVING

(People/Handling)

MMOVING(People/

Handling)IINVENTORYIINVENTORY

NNON-QUALITY(Inspection/Rework

Repair/Scrap)

NNON-QUALITY(Inspection/Rework

Repair/Scrap)

OOVER-

PRODUCTIONOOVER-

PRODUCTION WWAITINGWWAITING

It’s NOW TIME to eliminate Wastes!

Wastes hunting implementationConclusion

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APS Waste Hunting DH 201101 01

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