3. 3 MU
Muri Muda Mura
• Unevenness
• Unreasonableness • Unusefulness
• Shifts in demand
• A process, system, • An activity within
or delivery that
or facility designed a process that
lead to a service
beyond the physical does not add
or support
capacities of value, from the
process being
employees / perspective of the
sped up or slowed
equipment customer
down (unsteady)
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4. Taiichi Ohno
The Father of Toyota
Production System,
JIT, and Lean
Manufacturing
Identified the 7 types
of Muda
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5. What is Waste ?
Waste is “anything other than the minimum
amount of equipment, materials, parts,
space, and worker’s time which are
absolutely essential to add value to the
product.”
Shoichiro Toyoda
President, Toyota
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9. Waste Types (Contd.)
Transport
Movement of product that does not add value
Inventory
Ties up capital, takes valuable space,
requires moving, difficulty in finding material,
obsolescence, losses due to damage
Reduces customer responsiveness and
multiplies quality problems
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10. Waste Types (Contd.)
Motion
Movement of people that does not add value
Waiting
Idle time created when material, information, people,
or equipment is not ready
Under utilising talent
Under utilising employees’ potential (their creative
ideas)
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11. Waste Types (Contd.)
Over processing
Effort that adds no value from the customer’s
viewpoint
Defect
Work that contains errors, rework, mistakes or
lacks something necessary
Creating / correcting defects robs resources,
“chokes” flow
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12. Waste Types (Contd.)
Overproduction
Producing more than the customer needs
right now
Consumes valuable resources not
immediately needed
Hides other process problems (bad quality,
poor scheduling, poor delivery)
Builds inventory not needed
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13. Waste Hierarchy
By Reducing waste,
we minimise the load
on landfill and
transport
By sorting our wastes,
we make it easier to
Reuse and Recycle
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14. Lean Tool to remove Waste
Input Waste Lean Tool
Man Motion Standard Work
Walking 5 S’s
Waiting 3P (Product Preparation
Searching Process)
Machine Motion 3P
Setup/Change over Setup Reduction
Breakdown TPM
Material Inventory Pull System
Method Batch production Flow Production
Transportation One Piece Flow
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15. “It has been my observation that most
people get ahead during the time that
others waste.”
- Henry Ford
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