8 Wastes1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Over processing
6. Over production
7. Defects
8. Unused Human Potential
Rapid Site Assessment
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Transportation
2
Definition: Any movement of product that does
not add value
Example: Moving parts in and out of storage,
movement of parts between processes
Indicator: Batch Production, push production,
large storage areas, functional layout
Action to take: One Piece Flow, VSM, Point of
use storage
2
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Inventory
3
Definition: Any material or product that is not
needed to satisfy the current customer demand
Example: Excess raw materials, work in
process, finished goods,
Indicator: Long supplier lead times, lack of
visible flow, long setups, no ordering process
on shop floor
Action to take: Pull Systems, One Piece Flow,
VSM, SMED
3
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Motion
4
Definition: Any movement of people that does not
add value
Example: Searching for parts/tools/prints, sorting
materials, reaching for tools, lifting parts/boxes
Indicator: Workplace disorganization, poor
workstation design, unsafe workspaces, missing items
Action to take: 5S, Hoshin, VSM, Point of Use
Storage, Water-Spider
4
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Waiting
5
Definition: Idle time created when material,
information, people or equipment are not ready
Example: Waiting for parts, prints, inspection,
machines, repairs, information
Indicator: Push production, work imbalance,
centralized inspection, high downtime, no visible
production plan
Action to take: Work Balancing, SMED, TPM, In
process Inspection
5
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Over processing
6
Definition: Any effort that adds no value from the
customers viewpoint
Example: Multiple cleaning of parts, over-tight
tolerances, paperwork
Indicator: Delays between processes, No DFM
process involving employees, No standardized work
Action to take: VSM, One Piece Flow, Standardized
Work
6
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Overproduction
7
Definition: Producing more that the customer needs
right now
Example: Producing to forecast, producing to avoid
setups, batch production
Indicator: Forecast on shop floor, long setups,
inventory to cover breakdowns
Action to take: Pull Systems, Work Balancing, Hourly
Takt Targets, SMED
7
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Defects
8
Definition: Any effort to contain, rework or disposition
mistakes or errors
Example: Scrap, rework, customer returns, supplier
rejects
Indicator: Processes not defined and stable, Poor
handling and tracking of rejects/rework, Internal and
external defect rates not visible
Action to take: Standardized Work, DM Process,
Customer Focus Area, Shop Floor Problem Solving
8
Upper longeron location in F-15 forward fuselage
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Unused Human Potential
9
Definition: Any Losses due to lack of utilization of the
entire team in continuous improvement
Example: No cross-functional teams, top-down
management, no suggestion programs
Indicator: No Team communication areas, poor
understanding of priorities, employee resistance to
new ideas
Action to take: 5S, Daily Team Meeting, Suggestion
System, QRQC
9
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10
Example - Scorecard
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11
Example - Scorecard