Recognize and Eliminate eight types of waste in Lean Manufacturing with the help of M-Box

7 Wastes of Lean

“Lean Manufacturing” originally considered 7 types of waste:

Inventory waste

Waste of Overproduction

Waste of Waiting

Motion Waste

Transportation Waste

Defects Waste

Over-processing Waste

Over time, experts in the field have suggested considering an 8th waste:

Waste of Unused Talent

Taiichi Ohno created the Toyota system or Lean Manufacturing, and defined the original 7 wastes. Eliminating them is essential to become lean. 

"Value" in Lean Manufacturing

Understanding what “Value” means in the Lean context helps to recognize the presence of wastes in production processes. This implies seeing each process as its customer sees it, whether internal or external.

According to Lean Manufacturing, value is what the customer expects from a process (and for which they are willing to pay), everything else is waste.

Activities that, although necessary, such as an inspection, do not add value in the Lean context are called “incidental work” and should be minimized.

8 types of Waste in Lean Production

Waste of Overproduction

More is produced than what the client requires, generating inventories that the client does not need and a cost to maintain them.

Waste of Waiting

Any period of zero production. Some examples: a stopped machine waiting for something to continue producing, or an operator watching a machine work without doing anything.

Transportation Waste

Unnecessary movements of parts and raw materials are made during production, which can cause damage to them.

Waste of Unused Talent

Poor use of staff’s talent, knowledge and skills.

Over-processing Waste

Extra work is done on a product. Adjusting the same section of a piece of equipment twice or making a report that no one will consult are some examples.

Inventory waste

Excess raw material, inventories in process or finished products. They can cause long delivery times, damaged products, transportation and storage costs.

Motion Waste

Any unnecessary movement of personnel, for example, when searching parts and tools.

Defects Waste

Production of defective units that cannot be put on the market.

How to Eliminate Wastes of Lean in Production

In today’s economic environment, the customer determines the price and companies are forced to reduce their costs to stay profitable. To achieve this the wastes need to be eliminated.

Doing so also allows to achieve a continuous, synchronized, and flexible flow, which translates into a more productive, healthy and sustainable future.

How M-Box helps Eliminating Wastes of Lean in Manufacturing

With M-Box you will be able to identify the wastes in your operation as the basis for improvement actions and processes to eliminate them.

Eliminating Waste of Waiting

The statistics of unexpected stops per machine or work station (Uptime) and productive time per operator provided by M-Box, will allow working against waiting.

Learn More about Alert Tickets in M-Box System

Avoiding Waste of Overproduction

With the M-Box scheduling module, it becomes clear what exact quantities need to be produced on the level of production order down to each machine job. Also, the system shows the remaining quantities in ongoing productions. This helps to manage overproduction. 

Learn More about Orders and Jobs in M-Box System

Eliminating Inventory waste

The M-Box scheduling module facilitates the preparation of the necessary raw material at the machine level for the current production order.

Learn More about Orders and Jobs in M-Box System

Avoiding Motion Waste

The M-Box functionality of uploading files to projects, orders and jobs facilitates the execution of repetitive jobs and optimal preparation for part changes. The latest version of the files and work instructions are shared across the board to all team members. 

Learn More about Projects in M-Box System

Eliminating Defects Waste

The quantitative information about quality inspections, as well as immediate notifications about machine or quality problems pushed to the right officers help you to minimize quality defects.

Learn More about Production Reporting in M-Box System

Avoiding Over-processing Waste

With M-Box you can focus on the management of productivity and uptime of the assets through simple, actionable and top-line data. Get the reports that are useful to avoid over-processing

Learn More about Project Management Tool in M-Box System

Avoiding Waste of Unused Talent

The data can be organized per operator, per shift, per product in any of its combinations. With this you can establish training opportunities and balance work teams to make the most of the personnel’s talent avoiding Unused Talent Waste

Learn More about Labour Tracking Software in M-Box System

These are just a few of the examples where M-Box can help recognize and eliminate the wastes of Lean Manufacturing to boost your factory productivity.