The 8 Deadly Wastes

© Operational Excellence Consulting
THE 8 DEADLY WASTES
INVENTORY MOTIONTRANSPORTATION WAITING
OVER-PRODUCTION DEFECTSOVER-PROCESSING NON-UTILIZED TALENT

4© Operational Excellence Consulting 4
Learning Objectives
Understand the
key concept of
waste
Copyrights of all the images used in this presentation are held by their respective owners.
Learn to recognize
the eight types of
waste in your work
areas and
processes
Adopt a positive
attitude to waste
elimination
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What is Waste?
1

Work versus Waste
Value Add
Non-Value Add:
Incidental Waste
Non-Value Add:
Pure Waste
Focus here for
improvement

What is Value-Added?
Value-Added
• Is any activity that increases
the market, form, or function
of the product/service
• These are things the
customer is willing to pay for
Value Add
Non-Value Add:
Incidental Waste
Non-Value Add:
Pure Waste

How Does Waste Take Root?
We find solutions to conditions and then forget to change
the solutions when the conditions change, e.g. stopgap
solutions
Over time, when conditions change, we no longer
remember why we do certain things or what problem they
were intended to solve
Hence it is important to ask why, over and over again,
about everything we do. Only in this way will waste fail to
take root.

The 8 Types of Waste
INVENTORY MOTIONTRANSPORTATION WAITING
OVER-PRODUCTION DEFECTSOVER-PROCESSING NON-UTILIZED TALENT

The 8 Deadly Wastes in
Manufacturing
2

Waste in Manufacturing
Inventory stockpiling or building ahead of
schedule
Purchasing materials before they are
needed
Producing more to “make up” for
production losses such as defects
Delivering more than what was ordered
Unbalanced material flow
Exceeding scope of agreement
OVER-PRODUCTION
Producing more than
what the customer
needs

Ordering parts or products from distant
suppliers when closer options are
available
Sending unsold products from the store
back to the warehouse
Moving containers of materials
Carrying WIP over long distances
Moving in and out of storage areas or in
between processes
Multiple storage locations
Sub-optimal dispatch or routing
TRANSPORTATION
Moving raw materials
or documents or
traveling from one
place to another

Manufactured items that do not meet the
customer’s specifications
Products that are shipped to the wrong
address
Order entry errors, design errors,
engineering errors and mistakes
Scrap, rework, replacements and
inspections
Incorrect schedules and information
Extra people to inspect, rework or repair
DEFECTS
Scrap, rework, data
errors or missing
information in
documents

The 8 Deadly Wastes in Office
3

Waste in Office
Shelves of unused office supplies
Stacks of promotional literature or pre-
printed forms
Inventory of never-been-used office
equipment
Excess facilities, materials and information
Excess storage space
Obsolete databases, files and folders
Emails waiting to be read
Files waiting to be worked on
INVENTORY
Building or storing
extra products that
the customer has not
ordered

Waste in Office
Reaching, bending or unnecessary
motion due to poor ergonomics and
office layout
Walking to meeting room
Trips to printers and copiers
Searching for information in internet,
intranet or shared folders
Searching for tools, files and supplies
Handling paperwork
MOTION
Extra physical/mental
motion that does not
add value

Waste in Office
Employees do not have the opportunity to
learn new skills or utilize hidden ones
Employees are not involved in process
improvement or problem solving
Time is spent correcting errors or
responding to emergencies
Workers are not given the chance to
advance within the company
Narrowly defined jobs and expectations
Mismatched work functions with skill sets
NON-UTILIZED TALENT
Not using employees
full intellectual
contribution

“The most
dangerous kind of
waste is the waste
we don't
recognize.”
Shigeo ShingoThis document is a partial preview. Full document download can be found on Flevy:

Adopting The Necessary Attitude
Adopt an attitude that supports changing the way things
have always been done
It is very important that you understand that one purpose
of discovering waste is to take the frustration out of
your work
Adopt the 10 principles for improvement (see next 10
slides)

Think of how to do it,
not why it cannot be
done.
2
Source: Masaaki Imai

Correct mistakes at
once.
5

Ask “Why?” five times
and seek the root
cause.
8

“Whether you
think you can,
or you think you
can’t, you’re
right.”
Henry Ford

About
Operational Excellence
Consulting

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Appendix

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