STM

Quality
Limited

7 Wastes

TOTAL QUALITY MANAGEMENT

7 Wastes

Power Solutions
ABSL
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Waste

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Quality
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How often have you used the

expressions:
That was a waste of time!
or
That was a waste of money!
or
That was a waste of effort!
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Wasted Time

Just imagine if
we could
collect all the
time together
that we have
wasted in the
past How much time
would that be?

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Wasted Money

Just imagine if we
could collect all
the money
together that
we have wasted
in the past How much
money would
that be?

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Quality
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Wasted Effort

Just imagine if
we could
collect all the
effort together
that we have
wasted in the
past How much effort
would that be?

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The Problem With

Waste

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The problem with wasted time,

money & effort is:
When its gone
- its gone!

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Eliminating Waste

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So what can we do to

eliminate waste?

We first need to identify what

is & is not waste, then we can

look at ways of eliminating or
at least reducing waste.
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Identifying Waste in the

Workplace

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Operational Activity
Value added Operations
Any process that changes the nature,
shape or characteristic of the product
in line with customer requirements
e.g. Pressing, welding, heat treatment.
This is where we make a profit!
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Identifying Waste in the

Workplace

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Operational Activity
Non-Value added Operations
Work carried out which is necessary
under current conditions, but does not
increase product value.
e.g. Inspection, tool change,
maintenance.
This is where we make a loss!
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Value Added and

Non-Value Added operations

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The objective is to raise the ratio of

Value added operations to non-value

added operations and eliminate waste.
OPERATOR TIME
WASTE

NON-VALUE ADDED

VALUE
ADDED

ELIMINATE

MORE TIME FOR

OTHER ACTIVITIES

NON-VALUE
ADDED

VALUE
ADDED

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7W The Elimination of
Waste

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So, now we understand the

difference in value added & nonvalue added operations, what are the
benefits in eliminating all waste?

Reduced costs
Greater Capacity
Bottlenecks are identified
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7W 7 Types of Waste
1 Over-production

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2 Inventory
3 Transportation

4 Process
5 Idle Time
6 Operator Motion

7 Bad Quality
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7W 1. Overproduction
Over-production

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Producing more than is needed hides a

multitude of problems. Excessive set-up

times, machine faults, risk of producing
obsolete stock.
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7W 2. Inventory

Inventory

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Carrying stock attracts cost & storage

problems. Storage leads to stacking,

racking, sophisticated computers, bar
coding & automation, all for an activity
that adds no value to the product.
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7W 3.
Transportation

Transportation

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This may appear unnecessary but does add

value. Large transport is easily identified but

small transport such as manual labour may
not be so noticeable. These can be improved
by changes to the work environment.
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7W 4.
Process

Process

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Adds cost but no value - e.g.trimming &

moulding to a level that is beyond the

required standard adds extra time that
customers do not want to pay for.
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7W 5. Idle
Time

Idle Time

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Typically, waiting for products & services

from preceding operations, waiting for

work from their previous set-up or
waiting for cycles to finish, or meetings
to start.
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7W 6. Operator
Motion
Operator Motion

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Typically, single handed operations

where both should be used, stretching

unnecessarily or awkwardly and walking
between things. All of these take time or
use time poorly, none add value.
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7W 7. Bad Quality

Bad Quality

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Rejects are always produced by systems

and procedures created by management.

If operators fail it is because the process
allowed them to fail through inadequate
training or because the process was not
capable in the first place.
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STM
7W The Elimination of
Quality
Waste
Limited
So, now we understand the 7 wastes, we
can:
Produce only what is needed;
Carry only essential stock;
Use transportation more wisely;
Produce work to the standard required;
Plan our production processes;
Put our efforts to the best possible use;
Train to make quality work every time!
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