Lean manufacturing: 7+1 waste types 

Introduction

Optimizing the manufacturing process goes beyond mere cost savings; it is essential for the long-term success of a company through the development of more efficient work methods. The primary goal of optimizing production is to minimize the seven wastes associated with product manufacturing while maintaining high quality of the final product.

To improve productivity and enhance product quality, companies should transition from traditional paper-based methods to digital solutions. Implementing specialized software can provide greater flexibility, improved accuracy, and real-time updates, aligning with the principles of lean production. This transition facilitates smoother operations, particularly in complex production processes.

In this article, you will discover the most common types of waste in production and learn how to optimize resource management, including the implementation of effective software solutions.

The Key Concept of Lean

Muda, a Japanese term meaning “waste”, is a key concept in Operational Excellence and Lean Management, referring to activities that consume resources without adding value. Taiichi Ohno, the creator of the Toyota Production System, first identified these waste types. To achieve sustainable and efficient production, organizations must eliminate or minimize all non-value-adding activities. 

What are the 7 wastes of Lean?

The easiest way to remember seven wastes introduced by Ohno is by using the abbreviation TIM WOODS. Let’s look at the abbreviation in more detail.

• Transportation 

Transportation waste refers to any unnecessary movement of parts or finished products. Each additional instance of excessive movement increases the risk of delays or damage, which can lead to additional costs for time, space, and machinery.

Example. Moving raw materials multiple times between workstations.

• Inventory  

Excess inventory includes excessive stocks of raw materials, components, or finished products stored in warehouses and work-in-progress items held in case of an unexpected demand increase or to guard against delays and poor quality. However, maintaining a large amount of inventory waste often proves impractical, resulting in unnecessary expenses without adding value.

Example. Overstocking raw materials or finished goods.

• Motion 

The excessive movement of employees — such as walking long distances, searching for necessary tools, or navigating an ergonomically unfavorable workspace — results in wasted time and potential injuries. This motion waste can accumulate, negatively impacting productivity.

Example. Employees walking long distances between workstations.

• Waiting 

Waiting time occurs when goods or tasks are idle and not involved in the work process. Examples include equipment awaiting repairs, deliveries pending arrival, or documents waiting for signatures. These pauses can significantly hinder the overall efficiency of the production process.

Example. Workers waiting for a machine to finish or for materials to arrive.

• Overproduction

Overproduction is a major waste type that leads to the accumulation of unsold products, increasing costs related to storage, transportation, and the risk of defective items. Ohno regarded overproduction as a principal type of loss, often giving rise to other problems in the production process.

Example. Manufacturing more products than customer demand.

• Over processing 

Over processing involves performing unnecessary work that adds little to no value. For instance, manufacturers may add features that do not enhance the product’s value for the customer, resulting in increased costs without justification.

Example. Applying unnecessary polishing or finishing steps.

• Defects    

Defects in products can lead to rework or irreparable issues within an entire batch. Defective items often need to be returned to the production process for correction, which can disrupt workflows and increase costs.

Example. Products with quality issues that must be corrected or discarded.

Later, Ohno’s concept was supplemented by another type of waste: 

• Unused skills 

Unused skills occur when employees are assigned tasks that do not fully utilize their qualifications and expertise. This misalignment can lead to a significant waste of professional potential.

Example. Not involving workers in problem-solving or process improvement efforts.

Another way for easy memorisation of all 7 wastes of Lean (+1 additional) can be represented as an abbreviation DOWNTIME (Defects, Overproduction, Waiting, Non-utilised talent, Transportation, Inventory, Motion, Extra Processing).   

Strategies for Reducing 7+1 Wastes of Lean

Reducing waste is critical for enhancing efficiency and profitability in any organization. There are three main approaches to reducing wastes of Lean.

• Incorporating Continuous Improvement (Kaizen). This philosophy encourages businesses to consistently identify and eliminate waste through incremental changes. By fostering a culture of continuous improvement, organizations empower employees to scrutinize processes regularly, seeking out inefficiencies and proposing solutions. This ongoing evaluation not only enhances operational efficiency but also drives innovation, allowing businesses to adapt swiftly to changing market demands.
• Employee engagement. It is another cornerstone of effective waste reduction strategies. Involving the workforce in the process of identifying waste and suggesting improvements fosters a sense of ownership and accountability. When employees are encouraged to share their insights, they are more likely to identify areas of waste that management might overlook. This participatory approach can lead to more effective solutions, as frontline workers often have the most direct experience with operational challenges. Regular training sessions, workshops, and feedback loops can help cultivate an engaged workforce that actively contributes to the organization’s waste reduction efforts.
• Lean Tools. Such tools help visualize the flow of materials and information, enabling businesses to pinpoint bottlenecks and inefficiencies in their processes. For example, 5S, a methodology focused on organizing and standardizing the workplace, promotes cleanliness and efficiency, which can significantly reduce waste. Finally, implementing Just-in-Time (JIT) production minimizes excess inventory by aligning production schedules closely with customer demand, thereby reducing holding costs and waste. By integrating these strategies and tools, businesses can create a more efficient, responsive, and waste-free environment that enhances overall productivity and profitability.

How to implement Lean manufacturing? 

Implementing Lean manufacturing is straightforward: introduce digital solutions to eliminate waste in your processes. Focus on every action, including seemingly minor tasks, as they can contribute to inefficiencies within your overall manufacturing processes. One significant area to address is wasted motion, which can arise from excessive paper instructions and lists.

By transitioning to automated digital programs, you can streamline workflows, making operations more efficient and reducing the seven wastes identified in Lean methodology. This shift not only simplifies access to information but also fosters a more agile production environment. Ultimately, eliminating waste through digitalization enhances productivity and supports the goals of Lean manufacturing.

ProcessNavigation is an excellent example of such a program. It will help you quickly and remotely manage workflows at each of the production levels. It allows employees to intuitively understand the application and perform simple daily actions with the least amount of effort. 

Advantages of using such a program: 

• improving the quality of work at each stage, including increasing the number of high-quality final products; 
• reduced transportation time and waiting due to constantly available communication at all levels of production in the app; 
• detailed ready-made work instructions embedded in the application can reduce by 2 times the potential cost of creating a paper version. Thanks to this solution, employees can receive updated or augmented information in real time, which avoids overproduction and significantly increases the speed of work processes; 
• providing checklists in the application format will also allow you to quickly track material or goods losses; 
• transparency of the workflow, presented in the form of complete information about all production processes in just one application, but at the same time easy integration of employees 

Сompanies that want to minimize unnecessary losses, while maintaining or increasing the value of the final product, need to abandon the additional paper load. The appearance of paper instructions, lists, and documents can lead to a deterioration of the situation in all eight types of garbage. Digital work instructions and checklists in one application can help solve or at least reduce this problem. 

FAQ

Do you want to add value to your products by simplifying your work processes? 

ProcessNavigation allows you to minimize high employee turnover, difficulties in training staff, and a lack of transparency in managing and coordinating processes. Intuitive, flexible, affecting and linking all stages of production software helps your employees complete both the simplest and more complex everyday tasks with improved productivity.