Page 39
Volume 1, Issue 1
This is a major flaw that occurs unknowingly
with most manufacturers. This waste can tie up
significant working capital resources that can
be used for other business operations. Some
key causes of overproduction are:
These are non-value added activities within the
process. Causes of processing waste are:
Poor process control
Poor document control system
Producing to a forecast
Misunderstood customer needs
Misuse of automation
Poor process communication
Long set-up times
Excessive queue times
Just-in-case production
Just in-case logic
Unclear customer needs
Redundant approvals
Engineering changes
Producing to forecast
3) Waiting Wastes
Waiting waste is idle time that is created when
waiting for materials, equipment, product, etc.
Some key causes of waiting waste are:
5)Transportation Waste
Unbalanced workload
This is the waste incurred by transporting parts and
materials around the plant facility. Causes of transportation waste are:
Unplanned downtime
Poor plant layout
Excessive set-up times
Misaligned process flow
Poor supplier deliveries
Large batch sizes
Poor process quality
Producing to a forecast
Producing to a forecast
4)Non-Value Added Processing
6) Inventory Excess