As we saw in our last article of 2021/08/20 KAIZEN is more a state of mind than a real method.
However, the reduction of waste (MUDA) is a common thread in the continuous improvement process.
Muda refers to all activities that consume resources without creating added value.
- Overproduction: producing more than necessary.
- Waiting : products or operators who have to wait between two tasks or stages.
- Transport: moving materials, parts, products, documents or information that does not add value for the customer.
- Excessive processes: processes that are too complex in relation to the selling price.
- Overstocking: anything that is not essential to the task at hand.
- Movement: unnecessary movement of people, usually due to poor workstation ergonomics, which does not provide value to the customer.
- Defects: which require rework, additional control, scrapping, customer dissatisfaction, etc.
It is also possible to add an 8th : Under-use of skills..
Lack of training, rigid and authoritarian management, little motivation, recognition and involvement lead to under-utilisation of employees' skills, is a serious impediment to creativity and team spirit!
Shigeo Shingo a great expert in Lean Manufacturing said:
« The most dangerous waste is the one you don't see »
Seeing waste is the first step towards eliminating it!
Go to the field, follow the company's processes, map them... Human nature is like this: when we see a defect, a problem, a waste, we can no longer do as we did before, we look for and always find an adapted solution to eliminate it.