LeanSigma ® Facilitator Training Module 5 – Waste.

LeanSigma® Facilitator Training

Module 5 – Waste

Topics

Page

Lean Sigma Process . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Customer Perspective . . . . . . . . . . . . . . . . . . . . . . . . 4

Waste: Tim Wood . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Lean Sigma has six steps to optimize processes.

3

Value and waste are always viewed from the customer’s perspective.

4

Anything that is not value-added or businessnon value-added is waste.

Waste comes in many different forms. “Tim Wood” is an acronym that helps us remember the most common forms.

• Excess Transportation

• Excess Inventory - materials and information

• Unnecessary Motion

• Waiting

• Over-producing

• Over-processing

• Defects and rework

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Moving materials (Transportation)

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Characteristic:• Poorly designed floor space• Lack of communication• Inconsistent schedules• Large batch sizes• BottlenecksExample:• E-mailing files back and forth• Use of large carts to move

work

Definition:The movement of material or information from one function to the next that does not directly add value to the service

Waste of Excess Inventory: Material/Information

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Definition:Any supply in excess of customer requirements necessary to produce services

Characteristic:• Too many forms or paper• Too many copies• Extra space for storageExample:• Excess paper reports• Needless cc: on e-mail• Two forms used with the same

information• Duplicate copies of the same

file

When you remove the excess work-in- process, other wastes become visible.

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“Now You See It!”

Waste of Excess Motion

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Definition:Any movement of people or equipment that does not add value to the service

Characteristic:• Looking to find information,

supplies, or equipment• Multiple work stations to

perform one task• Too much search or walk timeExample:• Pulling information from

various sources to add into one

• Walking back and forth to an inconveniently placed fax machine

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Waste of Waiting

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Definition:Idle time that is produced when two processes are not synchronized

Characteristic:• Unbalanced workloads – some

steps take much longer than others

• Process flow stops due to unplanned interruptions

• Queues or idle time• Capacity doesn’t match

volumeExample:• Queues• Idle Time

Boarding a plane

Waste of Over-Producing

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Definition:Producing more than needed or producing faster than needed

Characteristic:• Extra information, supplies, or

equipment• Unbalanced workflow• Large batch sizes• You produce “just in case” you

need it.Example:• Running analyses before they

are needed• Preparing mortgage docs

before they are needed• Preparing a special report just

in case the client asks for it again.

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Waste of Over-Processing

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Definition:Effort which adds no value to a product or service

Characteristic:• Bottlenecks• Lack of understanding customer

needs• Endless refinement• Redundant approvals or checks

Example:• Reports produced, but not used• Recording the same information

on four different forms in a chart/system

• Reworking a Powerpoint deck over and over because the end-user’s needs are unclear

• Assigning work to an over-qualified resource

Waste of Errors (Defects) and Rework

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Definition:Rework or repair a service to meet customer’s requirements

Characteristic:• Extra manpower required to

rework, revalidate, repair• Missed deadlines• Poor customer relations• Reactive vs. proactive• Unpredictable process outcomesExample:• Encoding errors• Late deliveries • Rerunning jobs that fail

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