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UnderstandingMUDA, MURA and MURI
Module - 2
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MUDAMuda means WASTE
Waste refers to any activity that does notadd value.
Waste only adds to time and cost.
Waste blocks flow
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Things to Remember about Waste:
Waste is really a symptom rather than a root causeof the problem
Waste points to problems within the system(At both process & value stream levels)
Elements of production that add time, effort, cost,
but no value
Waste
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MUDA Waste of Overproduction
Waste of Inventory
Waste of Repair / Rejects
Waste of Motion
Waste of Processing
Waste of Waiting
Waste of Transport
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Waste of Overproduction
Producing Moreor Sooner or Faster
than needed
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Waste of Inventory
Any Supply inexcess of onepiece flow
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Waste of InventoryBut most of all it hides all other problems
LongTransportation
Abse
nteeism
Communi
cationProblem
Long SetUp Time
Lack ofhousekeeping
LineImbalance
Quality
Problems
VendorDelivery
MachineBreakdown
PoorScheduling
Raw Material
Sea ofInventory
Finishedproduct tocustomer
Losses
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Waste of Repair / Reject
Inspection or repair of a
product or service to fulfillcustomer requirements
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Waste of Motion
Any movement that does notadd value
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Waste of Processing
Effort which adds no additional
customer value to a part
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Waste of Waiting
Being idle betweenoperations
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Waste of Transportation
Any movement of material that
is not required for Just-In-Time production
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MURAMura means IRREGULARITY
Whenever a smooth flow of work isinterrupted in an operators work, the flow of
parts and machines, or the productionschedule, there is mura
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MURAMura means IRREGULARITY
It can occur in:
Production Parts flow
Equipment usage
Work done by team members
Information flow
Material deliveries, causing shortage oroverstock
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MURA Benefits of eliminating Mura:
Shorter Lead times
Lower WIP
Faster response time
Lower cost
Greater production flexibility
Higher quality
Better customer service
Higher revenue Higher throughput
Increased profit !
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MURA
WaitTime
Overburden !!
Balanced
Team Member A Team Member B Team Member C
Cycle
Time
245
Cycle
Time
520
Cycle
Time
425
Takt Time430
Tim
e5
4
3
2
1
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MURIMuri means strenuous conditions for both workers andmachines as well as for the work process.
When machines are overburdened
We run the risk of causing safety hazards, equipment breakdownsand manufacturing defects.
When team members are overburdened:
The safety of the team members can be endangered
Workers are more likely to become exhausted or fatigued
It becomes difficult for team members to do each job with attentionto detail. This increases the frequency of defects, which in turnadversely affects the quality.
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MURIMuri means STRENUOUS WORK A profusely sweating operator
Squeaking sound from the machine
A newly hired worker assigned to do the job of aveteran without adequate training
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Muda, Mura and Muri in Office
Concepts
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1.Overproduction
Generating more information than the customersneeds right now
More information than the customer needs
More information than the next process needs Creating reports no one reads
Making extra copies
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2.Transportation
Movement of information that does not addvalue
Retrieving or storing files.
Carrying documents to and from sharedequipment.
Taking files to another person.
Going to get signatures.
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3.Motion
Movement of people that does not add value Searching for files
Extra clicks or key strokes
Clearing away files on the desk
Gathering information
Looking through manuals and catalogs
Handling paperwork
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4. Waiting
Idle time created when material, information,people or equipment is not ready. Waiting for:
Faxes
The system to come back up
Copy machine
Customer response
A handed off file to come back
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5. Processing
Efforts that create no value from thecustomers view point
Creating reports
Repeated manual entry of data
Use of outdated standard forms
Use of inappropriate software
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6. Inventory
More information, project material on hand than thecustomers needs right now
Files waiting to be worked on
Open projects
Office supplies
E-mails waiting to be read
Unused records in the database
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7. Defects
Work that contains errors, rework, mistakes orlacks something necessary
Data entry error
Pricing error
Missing information
Missed specifications Lost records
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Peoples Waste
Not using peoples (mental, creative, physical,
skill) abilities.Causes:
Management by fear and directive, politics
Poor hiring practices
Low or no investment in training
Low pay, high turn over strategy.