Lean manufacturing is a popular business philosophy that is used to improve efficiency and eliminate waste in the production process. It has been applied to a variety of industries, from automotive to healthcare, and has become an important part of facilities management. The eight wastes of lean manufacturing are: overproduction, waiting, transportation, processing, motion, inventory, defects, and underutilized talent. By understanding and addressing each of these eight wastes, facilities managers can help their companies become more efficient and profitable.
Overproduction
Overproduction is the creation of more products or services than are actually needed. This waste is caused by producing too far in advance of customer demand or ordering excess materials and components. It can lead to an increase in costs and inventory, and can create a strain on production resources. To combat this waste, facilities managers should ensure that production is closely aligned with customer demand and that inventory levels are kept to a minimum.
Waiting
Waiting occurs when products or services are not available when they are needed, which can lead to delays in production. This often happens when components are not delivered on time or when machines are not functioning properly. Facilities managers can help reduce waiting waste by closely monitoring production schedules and ensuring that components and machines are fully operational.
Transportation
Transportation waste occurs when products or materials are transported between locations unnecessarily. This can lead to an increase in costs and can lead to delays in production. Facilities managers can help reduce transportation waste by optimizing routes and ensuring that materials are delivered on time.
Processing
Processing waste is caused by unnecessary or inefficient processes, which can lead to an increase in costs and delays in production. Facilities managers can help reduce processing waste by streamlining operations and ensuring that processes are efficient.
Motion
Motion waste occurs when workers are required to move between locations unnecessarily, which can lead to an increase in costs and delays in production. Facilities managers can help reduce motion waste by optimizing the layout of the facility and ensuring that materials are easily accessible.
Inventory
Inventory waste occurs when materials or components are not used in a timely manner, resulting in an increase in costs and delays in production. Facilities managers can help reduce inventory waste by closely monitoring inventory levels and ensuring that materials are used as soon as possible.
Defects
Defects occur when products or services do not meet customer expectations, which can lead to an increase in costs and delays in production. Facilities managers can help reduce defects by closely monitoring quality levels and ensuring that processes are efficient.
Underutilized Talent
Underutilized talent occurs when workers are not given the opportunity to develop their skills or utilize their full potential. This can lead to an increase in costs and delays in production. Facilities managers can help reduce underutilized talent by providing employees with training and development opportunities and ensuring that they are given the opportunity to reach their full potential.
Conclusion
The eight wastes of lean manufacturing can be a significant burden on production processes, leading to an increase in costs and delays in production. By understanding and addressing each of these eight wastes, facilities managers can help their companies become more efficient and profitable. Through careful monitoring and implementation of lean manufacturing principles, facilities managers can greatly reduce waste and lead their companies to success.