There are all kinds of waste on the job site, some you can detect, some you can't. In fact, the amount of waste you can detect is often only a small part of the iceberg. Most of the waste is hidden beneath the surface of the sea, hidden from you by the icebergs. In order to achieve lean production, we must find out the waste phenomenon in the work site.

The following figure lists some of the major waste at the work site:

一、Overproduction and waste

1. Definition: production is more than what the downstream customers need; Production is faster than downstream customers need

2. Features: material accumulation; Redundant equipment; Extra shelves; Surplus manpower

3. Reasons: insufficient processing capacity; Insufficient communication; Long changing time; Low utilization rate of working hours; Lack of stable production plan, etc

4. Harm: large inventories are produced

二、Inventory waste

1. Definition: any supply of materials beyond the processing requirements is inventory

2. Features: extra space; Sluggish logistics; Lots of rework; Response time to customers is slow, etc

3. Reasons: insufficient processing capacity; Long changing time; Local optimization; unpredictability

4. Harm: occupying funds and covering up management problems (inventory is the top 7 waste, the root of all evil)

三、Handling waste

1. Definition: all handling activities that do not conform to lean production, mainly referring to unreasonable in-plant logistics

2. Features: extra forklifts; Duplicate storage sites; Extra space; Incorrect inventory taking; Damage, etc

3. Reasons: improper planning; Long changing time; Lack of field management; Improper layout, etc. (the reasonable manual is less, the route should be short)

四、Inspection/rework waste

1. Definition: rework products or services to meet customer requirements

2. Characteristics: spend extra time; Wrong distribution of articles; Passive fire response, etc

3. Reasons: insufficient ability, improper operation and insufficient training

五、Improper waste of process

1. Definition: processes that do not add value to the end product/service

2. Features: process bottleneck; Unnecessary finishing; Unnecessary approval process; Excessive information processing, etc

3. Reasons: new technologies are applied in other processes; Improper decision-making level; Invalidation of rules and regulations; Lack of customer feedback etc

六、Waste of redundant action

1. Definition: any action of personnel and equipment that does not add value to the product or service

2. Features: find tools; Excessive bending; excessive bending. Materials and equipment too far away; Walking time; Hectic etc.

3. Reason: site layout; Poor site management; Low man-machine efficiency; Methods differ, etc

七、Wait for the waste

1. Definition: the free time generated by the failure to fully synchronize the two related elements

2. Features: people, etc.; Machine and so on; This person waits for that person; Uneven load; Fault shutdown; Stop waiting for material

3. Reasons: different working methods; Long changing time; Lack of resources; Low efficiency of personnel and equipment

Seven waste countermeasures

To find out the problem is the premise of solving the problem, enterprises should consciously observe and record the waste phenomenon in the work site, and then formulate countermeasures from the aspects of organization, process, process requirements, operation steps and so on: