Question

describe Ohno’s 7 wastes and how to eliminate each of them

Answer 1

Ohno's 7 wastes and possible measures to eliminate them

1. Overproduction- Amount of product produced which was not required.

How to eliminate-

1. Use improved forecasting methods, to forecast correctly, and hence produce approximately exactly how much is required

2. Pull Systems Scheduling can be used, producing only that much which is asked

3. Use Heijunka - level loading at all stations, and concepts like Total Productivity Management

2. Transportation

This involves movement of products within the manufacturing unit

How to eliminate-

1. Use signal methods like Kanban, which means item is only moved when required

2. Use proper material handeling equipment to reduce unwanted flow and also to optimize the flow

3. Motion

This is unwanted movement of people inside the manufacturing unit

How to eliminate-

1. Use time-motion study to identify the causes behind the time taken for the movement, and try and reduce the time by bringing in optimal movements

2. Design the workstations accordingly to reduce the movements

4. Waiting

Idle time in the manufacturing due to raw material/people/equipment etc. being not ready

How to eliminate it

1. Use Kaizen-continuous improvement, identify the causes of down time or idle time, and work upon them to reduce the idle time

2. Takt-time reduction can be done, to create an urge in the entire system to work to their optimal efficiencies

5. Processing

These are all such processes which add no value to the customers, and customer will not be willing to pay for that process

How to eliminate-

1. Use Value Stream Mapping, identify processes that are value adding and those which are non value adding. Eliminate the ones which are non value adding, and develop a new Value Added Process map for people to follow

2 Use Lean manufacturing methods as well, to reduce the extra wasteful processes

6. Inventory

Extra raw materials or finished or semi-finished goods stored, which will not be utilized by the customers, and would involve holding costs for the company to use them in the next period

How to eliminate-

1. Supplier development- so that supplier acts according to the production needs, and adjust the rates accordingly. THere is no need to store extra in order to reduce buying costs, which in turn increase the holding costs

2. Set-up time for machines can be reduced, which means more material in the same amount of time can be consumed, and there is no underproduction

7. Defects

These are the defective parts produced at the final stage, or mid stage, or anytime during the production

How to eliminate-

1. Use Six Sigma methods, to find the causes of defects and reduce the number of defects over the time by removing the under-lying causes

2. Use Total Quality Management techniques, which teach the staff about the importance of quality, and why there should never be compromise on the quality of good produced, just to produce some extra goods or save time. Imbibe the quality into the system

The question asked for the type of wastes, and how to eliminate them, which i have explained. If you are also willing to know the causes for these wastes, please post them in the comments, i would like to help you out.

Thank You