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Eliminate 8 Wastes of Lean Manufacturing: Boost Factory Productivity

ELIMINATE 8 WASTES OF LEAN
Every industrial facility generates waste in some form or another. However, not all waste has to be physical; some can appear within the processes that occur throughout the manufacturing cycle. It is critical that you adopt strategies that enable you to generate less waste.

“Lean is a way of thinking, not a list of things to do.”

– Shigeo Shingo, a Japanese Industrial Engineer

Lean manufacturing is a method for optimizing and simplifying the way a company operates and interacts with its surroundings on a strategic level. Additionally, it is an efficient method of decreasing and managing existing waste within an organization.In this article, we'll look at the eight types of waste in lean manufacturing and the lean tools that may help reduce them and improve the precision and customer focus of your business operations. 

How to Eliminate the 8 Types of Waste in Lean Manufacturing


Transport

Transport is a prominent example of lean manufacturing waste. It may be from machining to welding, or from a factory in China to an assembly line in America. This transportation adds no value to the product, does not alter it, and does not satisfy the customer. Transport waste may cause your firm to lose money rapidly; you must spend on material handling equipment, employees, training, safety precautions, additional space for material transportation, etc. Transportation requires strategic planning and logistical assistance to be lean and optimum. Transportation performance should be monitored routinely using analytical measures and KPIs.

For example, Toyota's Toyota Production System (TPS) has developed the tools and practices of Lean Manufacturing, and many of its suppliers are located near to their factories, which helps them reduce the transportation waste of their business. To start applying lean thinking to transportation management, you must first understand transportation expenses, which are divided into unit and productivity costs. Focus on long-term solutions that reduce overall mileage, trailer use, waiting times, and adherence to routing guides. Value stream mapping can help locate transportation waste. With value stream mapping, processes are documented and evaluated in terms of customer value. Any transportation that cannot be connected to value is reduced or eliminated.

Inventory

One of the main benefits of current Point of Sales (POS) and production technologies is that companies may produce things only when there is demand. Inventory waste is no longer an unavoidable issue. When this type of lean manufacturing waste occurs, it is usually the result of excessive production or a process breakdown. Order management and inventory monitoring solutions assist in decreasing inventory waste. Creating real-time inventory visibility and accuracy requires the use of a computer-based system, such as ERP software.

Additionally, it has been demonstrated that scanning barcodes significantly reduces errors associated with manual procedures. This type of solution offers a far more detailed and fast inventory tracking strategy. Moreover, an active cycle counting program is critical for a manufacturing company's inventory management to improve.

Movement/ Motion

Movement/motion waste is the unnecessary transport of objects. Motion waste, on the other hand, also refers to unnecessary human actions or movements. Motion waste is commonly caused by unoccupied or untidy workspaces. To address motion waste, lean practitioners invented the 5S method. It decreases workplace inefficiency and motion waste. Each of the five steps in the 5S technique begins with the letter S, which are:

  • Sort: Removing unnecessary material from each work area.
  • Set in Order: Set the goal of creating efficient work areas for each individual.
  • Shine: Maintaining a clean work area after each shift helps in identifying and resolving minor concerns.
  • Standardize: Documenting changes to make applications in other work areas more accessible.
  • Sustain: Repeat each stage for continuous improvement.

Waiting

Waiting time occurs when two interrelated processes are out of sync. This may include waiting for parts, instructions, labor, or repairs. Total Productive Maintenance (TPM) is a comprehensive approach that helps to eliminate waiting by reducing equipment downtime. It emphasizes empowering operators by assisting them in maintaining their own equipment. This method promotes shared accountability and increases the involvement of frontline workers.

Over-production

Overproduction happens when there is a surplus of goods produced. Overproduction is a major source of waste in the 8 wastes examples of lean. It is costly, reduces quality, and generates other wastes such as inventory and transportation. Kanban is another lean manufacturing approach designed to decrease overproduction waste. Kanban is a Japanese word that means “visual board”. As the name suggests, this approach initiates action based on visual clues. It is a "pull" method that addresses demand rather than anticipating it. Additional inventory is generated only when existing inventory is "pulled" from stock.

Over-processing

When simple processes are replaced by complex ones, this is known as over-processing. Excessive processing might entail the addition of features to products that buyers do not require. The employment of expensive equipment that isn't strictly necessary is another example of excessive processing. Value stream mapping may be quite beneficial for locating instances of excessive processing. It assists manufacturers in developing a sound action plan to leverage their available resources while also ensuring that materials and time are spent efficiently.

Defects

Defects in manufactured products are expensive to repair since the damaged product must be scrapped or re-made, interrupting the manufacturing process. Lean manufacturing approaches strive for a zero-defect output by recording problems, determining their causes, and adopting corrective action. There are several strategies for identifying and eliminating defect wastes; nevertheless, lean manufacturing seeks to prevent them from developing in the first place. This defect prevention is accomplished through a variety of techniques ranging from automation / Jidoka (machines with "human" intelligence that can detect when a non-standard event has occurred) to Pokayoke devices that detect if a product is defective, either preventing the process from running or highlighting the defect for action.

Implementing standard operating procedures (SOP) and training to guarantee that the proper processes are used and standards are fulfilled is, once again, the greatest solution for overcoming defective waste. Defects are an obvious waste. The cost of materials and labor utilized to create a product gets wasted. The waste from faulty products is aggravated by returns, lost goodwill, and wasted customer support activities.

Untapped Talent

Employees are the most significant resource in any organization. The lean waste of untapped talent is just what it sounds like: not leveraging your precious resource, your personnel, effectively or at all. This produces waste by leaving value on the table that your workers may provide through unrecognized abilities or talents. Recognizing and utilizing your team's abilities, expertise, and talents is critical to business success. Employees are your most precious resources, and not fully using them wastes time and money. Inappropriate task assignments are one typical source of talent waste.

Additionally, unnecessary administrative chores, poor communication, ineffective leadership or teamwork, and inadequate training are further untapped talent lean wastes examples. The greatest method to reduce talent waste is to empower employees rather than micromanage them. Many unseen abilities and talents emerge when employees feel empowered, making it simpler to identify and develop accessible talent. Following are a few ideas that can be adapted to any workplace:

  • Refine training programs.
  • Set up process management checklists that allow for flexibility.
  • Create remote monitoring systems to reduce micromanagement.
  • Hold frequent team meetings so they may express their views and ask questions.

How Did Nike Benefit from Lean Manufacturing?

According to the company's FY10/11 Sustainable Business Performance Summary, the supply chain has run more effectively after adopting a lean strategy. They termed it "better manufacturing" as it eliminated wasted resources and time. As part of its sustainability mission, the study noted, the corporation attempted to remove waste, wasted time, and materials from its processes.
According to the survey,

  • Failure rates were 50% lower in contracted factories that used the lean strategy than in companies that did not.
  • It was shown that lead times for deliveries from lean manufacturing were on average 40% shorter.
  • Lean factories have also claimed gains in productivity of 10% to 20% and a 30% decrease in the time required for launching a new model.

Final Words

We've discussed the lean strategies to deal with the eight forms of waste in manufacturing.  Identifying the lean manufacturing types of waste is critical for evaluating business loopholes and overcoming impediments to company growth.

Despite the industry’s transition journey from 1.0 to 4.0, many manufacturing professionals agree that lean manufacturing is still applicable today for running a business with the least amount of resources necessary to thrive. It is ideal for businesses looking to stay ahead of emerging industry trends, such as new technology and associated workforce shifts. By using Lean concepts, technologies, and digital operations, businesses may increase their agility and customer focus.

FAQ


How is lean different from Six Sigma?

Lean aims to reduce waste, speed up operations, and improve flow. Six Sigma lowers variation and lean decreases waste. Six Sigma targets 3.4 defects per million opportunities, whereas lean emphasizes speed.

What are the five principles of lean manufacturing?

According to Womack and Jones, there are five key lean principles: value, value stream, flow, pull, and perfection.

What is the objective of lean manufacturing?

Companies looking for ways to enhance efficiency and reduce waste should adopt lean thinking. The ultimate objective of lean manufacturing is to manufacture excellent goods that satisfy customers while using minimal resources.

Spotlight

Nikon

Nikon Corporation, is a multinational corporation headquartered in Tokyo, Japan specializing in optics and imaging. Its products include cameras, binoculars, microscopes, measurement instruments, and the steppers used in the photolithography steps of semiconductor fabrication. It was founded in 1917 as Nippon Kōgaku Kōgyō Kabushikigaisha (日本光学工業株式会社 "Japan Optical Industries Corporation"); the company was renamed Nikon Corporation, after its cameras, in 1988. Nikon is one of the major companies of the Mitsubishi Group.

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Stratasys’ Latest Printer Offers Applications with Improved Parameters

Stratasys | November 06, 2023

Stratasys introduces the F3300 3D printer, offering high speed, uptime, and quality for targeting manufacturing industries with high demands. The F3300 empowers manufacturers to accelerate product development and address global supply chain challenges, delivering a strong return on investment. The latest printer will be unveiled during a live event hosted by the company on November 7. Stratasys, a leader in additive manufacturing and polymer 3D printing solutions will showcase its latest F3300 Fused Deposition Modeling (FDM) 3D printer at the Formnext conference, held in Germany from November 7 to 10. This printer offers exceptional value to manufacturing customers with reduced labor, higher part quality and yield, as well as maximized uptime. The solutions provided by Stratasys provide customers a competitive edge at every stage of the product value chain. These solutions include smart and networked 3D printers, polymer materials, a software ecosystem, and components on demand. The most successful companies in the world go to Stratasys to improve health care, provide agility to manufacturing and supply chains, and alter product design. Key Advancements Faster Print Speeds: Increased gantry speeds, speedier extrusion rates, and autocalibration. Higher Part Quality and Yields: Up to 25% improvement in accuracy and repeatability with autocalibration. Maximized Uptime: Machine monitoring, extruder redundancy, and an operator-friendly interface design. Cost Savings: Offers 25-45% savings compared to other Stratasys FDM solutions. Rich Garrity, Stratasys' Chief Industrial Business Unit Officer, remarked that the next-generation AM system empowers customers to scale production and reduce the need to compromise between traditional and additive manufacturing solutions. He added that the conventional capacity limitations, rising global supply chain challenges, and application complexity are incredibly stressful for manufacturing, and F3300 will empower buyers to accelerate product development, allowing faster innovation and maximized ROI. F3300 printer expands the range of production capabilities and provides performance-oriented manufacturers with the most expansive variety of best-in-class FDM printers. The F3300 is the latest addition to the FDM family, which includes the F900, F770, F450mc, and the F123 series. F3300 complements Stratasys’ F900, known for its dependability, use of high-performance materials, and large capacity. Built for manufacturing by the inventors, the F3300 will be the most sophisticated industrial 3D printer in the market. Its advanced features and design will transform how additive manufacturing is used in demanding industries like automotive, government/military, aerospace and service bureaus. The F3300 is expected to be available for shipment from 2024. Stratasys will host a live event on November 7 at 5:30 p.m. CET to uncover the F3300.

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Operations

Accruent Eases Manufacturing Ops with Centralized Asset Management

Accruent | September 13, 2023

Accruent, a leading provider of intelligent solutions for the built environment, has announced the full integration of its Maintenance Connection CMMS with the Meridian engineering document management system (EDMS) and vx Observe IoT platforms. This integration marks a significant step in Accruent's commitment to enhancing efficiency and collaboration among operations, maintenance, and engineering teams in the manufacturing industry while ensuring compliance. Chief Product Technology Officer at Accruent, Richard Leurig, remarked, We are excited to introduce this transformative integration that exemplifies our commitment to innovation, collaboration, and regulatory compliance. [Source: GlobeNewswire] He added that by integrating seamlessly the Maintenance Connection, Meridian, and vx Observe, they empower their customers with a comprehensive solution that boosts their operational efficiency and helps them navigate the complexities of regulatory standards. This empowers maintenance teams to efficiently manage asset documentation, access IoT data, and achieve compliance with industry standards, ultimately improving operational efficiency. Traditionally, users of Computerized Maintenance Management Systems (CMMS) faced challenges when switching between CMMS platforms and engineering document management or IoT software. This often led to inefficiencies and difficulties in accessing critical documents on-site. By integrating Accruent's EDMS and IoT solutions with Maintenance Connection CMMS, a centralized platform is created. This enables maintenance teams to effortlessly access, visualize, update, and review all asset documentation from a single location, significantly reducing downtime and enhancing technician efficiency. The IoT integration also provides easy access to energy and remote monitoring for early detection and resolution of potential asset failures. Accruent's integration solutions are designed to streamline operations in manufacturing industries, benefiting organizations worldwide. This integration aligns with Accruent's commitment to innovation, collaboration, and regulatory compliance. These integrations are part of a broader initiative to help organizations achieve compliance under 21 CFR part 11. Accruent's dedication to providing cutting-edge technologies underscores its commitment to helping organizations succeed and address industry-specific challenges in the manufacturing sector. About Accruent Accruent is globally renowned as the foremost provider of software solutions that unify the built environment. Their comprehensive offerings encompass workplace management, asset management, and both physical and digital applications. Accruent is at the forefront of redefining how organizations harness data to revolutionize facility and asset management practices. It provides solutions to a customer base of over 5,000 organizations spanning industries in more than 150 countries.

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Manufacturing Technology

Rockwell Automation Invests in Momenta Fund for Sustainable Tech

Rockwell Automation | November 08, 2023

Rockwell Automation invests strategically in Momenta's Industry 5.0 Fund, focused on resilient, sustainable, and human-centric industrial operations. The Industry 5.0 Fund promotes a transition from shareholder to stakeholder value, emphasizing sustainability and empowering individuals with technology to make informed decisions. This partnership positions Rockwell Automation to gain early access to innovative technologies that have the potential to disrupt industrial markets and enhance sustainability while supporting startups at the forefront of digital transformation in energy, manufacturing, smart spaces, and supply chains. Rockwell Automation, a global leader in industrial automation and digital transformation, has made a strategic investment in Momenta's Industry 5.0 Fund. The Industry 5.0 Fund, with an initial capital of $100 million, supports startups dedicated to advancing resilient, sustainable, and human-centric industrial operations. Switzerland-based Momenta launched the fund in cooperation with the EU Commission to promote research and innovation in line with the Commission's Industry 5.0 initiative. The fund aims to transition industries to focus on stakeholder value over shareholder value, emphasizing sustainability and empowering people with information and technology for decision-making. Targeting entrepreneurs in Europe and North America who are at the early stages of development and are at the forefront of the digital revolution in energy, manufacturing, smart spaces, and supply chains, the Industry 5.0 Fund will provide them with venture capital funding and direct value creation. Rockwell Automation is an anchor investor in the fund, allowing the company early access to cutting-edge technologies that can disrupt industrial markets and enhance sustainability. The investment aligns with Rockwell's strategy for inorganic growth and provides valuable insights into next-generation technologies driving digital transformation. Cyril Perducat, Senior Vice President and Chief Technology Officer of Rockwell, expressed excitement about partnering with Momenta to support startups poised to disrupt the industry while expanding human potential. He emphasized the intrinsic benefits of adopting technology that benefits all stakeholders. Ken Forster, a founding partner at Momenta, expressed his appreciation for Rockwell Automation's investment in their Industry 5.0 fund. He acknowledged that Rockwell Automation played a defining role in industrial automation and digital transformation within North America. Under the leadership of an impressive team, they had also been extending their global influence. Ken noted that Momenta's primary focus for the past decade had been investing in companies that drive industrial impact. He further mentioned that they couldn't have found a better partner for the Industry 5.0 fund than Rockwell Automation.

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Manufacturing Technology

Stratasys’ Latest Printer Offers Applications with Improved Parameters

Stratasys | November 06, 2023

Stratasys introduces the F3300 3D printer, offering high speed, uptime, and quality for targeting manufacturing industries with high demands. The F3300 empowers manufacturers to accelerate product development and address global supply chain challenges, delivering a strong return on investment. The latest printer will be unveiled during a live event hosted by the company on November 7. Stratasys, a leader in additive manufacturing and polymer 3D printing solutions will showcase its latest F3300 Fused Deposition Modeling (FDM) 3D printer at the Formnext conference, held in Germany from November 7 to 10. This printer offers exceptional value to manufacturing customers with reduced labor, higher part quality and yield, as well as maximized uptime. The solutions provided by Stratasys provide customers a competitive edge at every stage of the product value chain. These solutions include smart and networked 3D printers, polymer materials, a software ecosystem, and components on demand. The most successful companies in the world go to Stratasys to improve health care, provide agility to manufacturing and supply chains, and alter product design. Key Advancements Faster Print Speeds: Increased gantry speeds, speedier extrusion rates, and autocalibration. Higher Part Quality and Yields: Up to 25% improvement in accuracy and repeatability with autocalibration. Maximized Uptime: Machine monitoring, extruder redundancy, and an operator-friendly interface design. Cost Savings: Offers 25-45% savings compared to other Stratasys FDM solutions. Rich Garrity, Stratasys' Chief Industrial Business Unit Officer, remarked that the next-generation AM system empowers customers to scale production and reduce the need to compromise between traditional and additive manufacturing solutions. He added that the conventional capacity limitations, rising global supply chain challenges, and application complexity are incredibly stressful for manufacturing, and F3300 will empower buyers to accelerate product development, allowing faster innovation and maximized ROI. F3300 printer expands the range of production capabilities and provides performance-oriented manufacturers with the most expansive variety of best-in-class FDM printers. The F3300 is the latest addition to the FDM family, which includes the F900, F770, F450mc, and the F123 series. F3300 complements Stratasys’ F900, known for its dependability, use of high-performance materials, and large capacity. Built for manufacturing by the inventors, the F3300 will be the most sophisticated industrial 3D printer in the market. Its advanced features and design will transform how additive manufacturing is used in demanding industries like automotive, government/military, aerospace and service bureaus. The F3300 is expected to be available for shipment from 2024. Stratasys will host a live event on November 7 at 5:30 p.m. CET to uncover the F3300.

Read More

Operations

Accruent Eases Manufacturing Ops with Centralized Asset Management

Accruent | September 13, 2023

Accruent, a leading provider of intelligent solutions for the built environment, has announced the full integration of its Maintenance Connection CMMS with the Meridian engineering document management system (EDMS) and vx Observe IoT platforms. This integration marks a significant step in Accruent's commitment to enhancing efficiency and collaboration among operations, maintenance, and engineering teams in the manufacturing industry while ensuring compliance. Chief Product Technology Officer at Accruent, Richard Leurig, remarked, We are excited to introduce this transformative integration that exemplifies our commitment to innovation, collaboration, and regulatory compliance. [Source: GlobeNewswire] He added that by integrating seamlessly the Maintenance Connection, Meridian, and vx Observe, they empower their customers with a comprehensive solution that boosts their operational efficiency and helps them navigate the complexities of regulatory standards. This empowers maintenance teams to efficiently manage asset documentation, access IoT data, and achieve compliance with industry standards, ultimately improving operational efficiency. Traditionally, users of Computerized Maintenance Management Systems (CMMS) faced challenges when switching between CMMS platforms and engineering document management or IoT software. This often led to inefficiencies and difficulties in accessing critical documents on-site. By integrating Accruent's EDMS and IoT solutions with Maintenance Connection CMMS, a centralized platform is created. This enables maintenance teams to effortlessly access, visualize, update, and review all asset documentation from a single location, significantly reducing downtime and enhancing technician efficiency. The IoT integration also provides easy access to energy and remote monitoring for early detection and resolution of potential asset failures. Accruent's integration solutions are designed to streamline operations in manufacturing industries, benefiting organizations worldwide. This integration aligns with Accruent's commitment to innovation, collaboration, and regulatory compliance. These integrations are part of a broader initiative to help organizations achieve compliance under 21 CFR part 11. Accruent's dedication to providing cutting-edge technologies underscores its commitment to helping organizations succeed and address industry-specific challenges in the manufacturing sector. About Accruent Accruent is globally renowned as the foremost provider of software solutions that unify the built environment. Their comprehensive offerings encompass workplace management, asset management, and both physical and digital applications. Accruent is at the forefront of redefining how organizations harness data to revolutionize facility and asset management practices. It provides solutions to a customer base of over 5,000 organizations spanning industries in more than 150 countries.

Read More

Events