8 WASTES (DOWNTIME) in Lean Manufacturing / MUDA in Manufacturing

What is MUDA??

👉An activity which does not adding any value in spite of using all resources. / An activity which turn down to value addition. / An activity for which Customer not paying. 

WASTES are obstacles to Lean manufacturing flow which increase process Lead Time & reduce organisation profitability.

Wastes / Non Value Added Activity 

DOWNTIME

DEFECT, OVERPRODUCTION, WAITING, NON UTILSE TALENT, TRANSPORT, INVENTORY, MOTION, EXTRA PROCESSING

DEFECT - त्रुटि

Product / Services not as per customer need. OR Product / Services are out of standards.

IMPACT - 

1. Reduce Productivity.

2. Required extra resources (like..Time, M/P ,Electricity, Air, Materials) for rework.

3. Scrap generation.

4. Customer satisfaction.

CAUSES - 

1. Inadequate Process & Quality Controls.

2. Lack of Skills & Work Standards.

3. Communication gap for Customer demands.

PREVENTION - 

1. Process & Quality Improvements through Adequate Controls.

2. Skills upgradation through Trainings.

3. Availability of Adequate Work Standards.

4. Proper Communication of Customer demands.

OVERPRODUCTION - अधिक उत्पादन

Produced products earlier in excess qty then customer need  OR 

Production before the need / demand.

IMPACT - 

1. Unwanted Inventory carrying cost.

2. Unwanted space accumulation.

CAUSES - 

1. Imbalanced production flow.

2. Long setup time.

3. Communication gap for Customer demands.

PREVENTION - 

1. Production rates balancing through TAKT Time.

2. Setup time reduction.

3. Define SFG/FG norms as per Customer demands.

WAITING - प्रतीक्षा

Production / Service flow on hold due to insufficient input for people / equipments OR

Next stations people/equipments  are not ready to work.

IMPACT - 

1. Underutilisation of Man / equipments.

2. Productivity loss.

CAUSES - 

1. Imbalanced production flow.

2.  Poor layout & skill lacking.

3. Slow & High setup times.

4. Poor communications.

PREVENTION - 

1. Balanced production layout for continuous material flow.

2. Well design layout & multi skilling.

3. Predefine Setups.

NON UTILISED TALENT - निष्क्रिय प्रतिभा 

People not deputed on job as per their skill OR underutilisation of Talent / skill / knowledge. 

IMPACT - 

1. Productivity & Quality loss.

2. Can not achieve Operational effectiveness.

3. Organisation profitability will decrease.

CAUSES - 

1. Poor Management policies for employee Job description.

2. No TEI initiatives.

3. Lacking of TNI reviews.

PREVENTION - 

1. Job allocation policies should be as per skill.

2. Employee engagement for process / layout design & improvements.

3. Training provision as per TNI reviews.

TRANSPORT - परिवहन 

Excess / Unnecessary  movement of materials & equipments from one place to another.

IMPACT - 

1. Product / Equipments damages.

2. Productivity Loss.

3. Ineffective use of Time / Manpower / Equipments.

CAUSES - 

1. Improper(more distance) Machine Layouts.

2. ZigZag process flow.

3. Multi location for material storages.

PREVENTION - 

1. Minimise distance between Equipments as feasible.

2. Established Linear process flow.

3. Implement SPF from plant inward to outward.

INVENTORY - उत्पाद

Excess / Unnecessary quantity of materials(R/M, SFG & FG). 

IMPACT - 

1. Defects.

2. Unwanted Cost of storage.

3. Unwanted Space accumulation.

4. Hindrance to smooth workflow.

CAUSES - 

1. Extra purchasing / Ineffective material scheduling to suppliers.

2. Due to Overproduction.

PREVENTION - 

1. Purchasing schedule as per real need.

2. Improve Takt time balancing between production lines.

MOTION - गति 

Excess & Unnecessary Movement of people from one place to another or turning & bending in  workstations.

IMPACT - 

1. Operator Fatigue.

2. Less productivity & Quality.

3. Underutilisation of resources due to High lead time.

CAUSES - 

1. Improper Line Layouts / Unorganised workplace.

2. Poor Ergonomics.

3. Non standardised operating procedures.

PREVENTION - 

1. Linear & balanced line layouts.

2. Implementation of  Healthy & safe workplace through motion study.

3. Implementation of SOP.

EXTRA PROCESSINGS - अत्यधिक प्रक्रिया   

 Performing extra work / quality on product than required by customer. 

IMPACT - 

1. Operator Fatigue.

2. Less productivity & Quality.

3. Underutilisation of resources due to High lead time.

CAUSES - 

1. Non standardised operating procedures.

2. Lacking of skill.

3. Communication gap.

PREVENTION - 

1. Well defined SOP.

2. Adequate trainings about product & process specifications.