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Lean practice training

The document outlines the concept of Lean and the importance of identifying and eliminating the 8 Wastes, known as TIMWOODS, to enhance efficiency and reduce costs. The eight wastes include Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, and Skills, each with specific negative consequences for businesses. By recognizing and addressing these wastes, organizations can streamline processes and improve overall productivity.

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0% found this document useful (0 votes)
5 views

Lean practice training

The document outlines the concept of Lean and the importance of identifying and eliminating the 8 Wastes, known as TIMWOODS, to enhance efficiency and reduce costs. The eight wastes include Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, and Skills, each with specific negative consequences for businesses. By recognizing and addressing these wastes, organizations can streamline processes and improve overall productivity.

Uploaded by

varun
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Ivan Carillo

LEAN

HOW TO IDENTIFY AND CUT THE WASTES


{saving 100s of thousands of dollars}
Ivan Carillo

Do you want brilliant processes that

+make simple flows


+get maximum output
+waste minimum resources

...at scale?

Then, start recognizing the 8 Wastes of


Lean - also referred to as TIMWOODS.

WHAT IS WASTE?

Waste can be defined as...

“any activity which doesn’t add value


to the customer or that the customer isn’t
willing to pay for”

Lean aims to remove all the wastes from


your work processes.
Ivan Carillo

TIMWOODS
It’s an acronym for

Transportation
Inventory
Motion
Waiting
Overproduction
Overprocessing
Defects
Skills

Originally there were seven wastes identified by Taiichi


Ohno as part of the Toyota Production System (TPS).

An eight waste, ‘Underutilized Talent’ or ‘Skills’, was


later introduced in the 1990s.

Being able to see these wastes is always the first


step.

Here are all of them in detail:


Note: Jean Cunningham and others use another acronym, “DOWNTIME”, to help
remember the types of Lean waste.
Ivan Carillo

1. Transportation
Unnecessary movement of products, equipment, and
materials within a process.

It adds unnecessary time to the flow,


while increasing the risk of

-being lost
-being placed in the wrong location

Transportation waste leads to various negative


consequences, including:

-Lost time and labour


-Increased costs
-Product damage and loss
-Delivery delays
Ivan Carillo

2. inventory
Excess products and materials not being processed.

It’s a pure cost; money just sitting around in the form of

-Raw Materials (0% Complete),


-WIP (Partially Completed)
-Finished Goods (100% Complete).

Inventory waste leads to various negative


consequences, including:

-Ties up capital
-Occupies space
-Increased lead times
-Risk of obsolescence or damage
-Reduced flexibility
Ivan Carillo

3. MOTION
Unnecessary movement by people (e.g. walking).

Motion is endemic in almost every business process.

Just sit somewhere and watch people walking around.

Motion is different from Transportation.

Motion relates to the people, whereas transportation


looks at the goods being transported.

This waste has several negative consequences:

-Increased wear and tear


-Additional costs for maintenance
-Risk of accidents due to fatigue
-Reduced productivity
-More quality errors
Ivan Carillo

4. waiting
Wasted time waiting for the next step in a process.

Time that the product is sitting there – not being


transported or processed.

Or the time that people are simply waiting for the


product to arrive.

If motion is endemic then waiting is a virus.


It destroys flow and value.

Waiting has several negative consequences:

-Increased costs
-Reduced productivity
-Delays
Ivan Carillo

5. overproduction
Making more than is necessary or needed by the
customer or the next step in the process

Overproduction is the King of Waste.

It has several negative consequences:

-Ties up capital
-Increased storage
-Obsolescence
-Increased movement costs
-Reduced flexibility

Many other wastes are created when you produce more


than the market demands.

Overproduction becomes more serious as customer


requirements continually change faster and faster.
Ivan Carillo

6. overprocessing
Doing more to the product than is necessary. Doing more
than the customer is paying for.

This can refer to

-doing more work


-adding more components
-having more steps than required

The negative effects of overprocessing waste include:

-Increased costs for labour, materials, and equipment


-Reduced productivity and efficiency
-Potential damage to customer relationships
-Reduced flexibility to adapt to changes

Overprocessing is as much an issue among internal


customers as it is with external customers.
Ivan Carillo

7. DEFECTS
Imperfect production that requires re-work, or doing
work again.

Defects are ‘any step within a process which is not done


correctly and requires some form of re-work or to be
done again’.

It’s the waste everyone can more easily identify with.

And without doubt, defects cost every business a huge


effort to fix.

The rule of thumb is the 1:10:100 rule which says that


an error spotted immediately will take x$ to fix.

If it’s missed and caught at the next step in the process


it will be x10.

Even later in the process, it will be x100.


Ivan Carillo

8. SKILLS
Not using people’s talents, skills and knowledge at their
full.

It’s often associated with poor management practices


(e.g. assigning employees the wrong tasks)

Every business has a huge amount of untapped talent


that can make a difference in long-term survival.

Non-utilized talent can also result from poor


communication and a lack of employee engagement.

You may have people stuck in roles which do not match


their strengths.

Check carefully.
Ivan Carillo

REPOST THIS
AND FOLLOW ME FOR DAILY POSTS ABOUT LEAN,
CONTINUOUS IMPROVEMENT AND INNOVATION

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