The 8 Wastage – MiNT “O” DEW

Posted on: January 3rd, 2018  /  By:  /  Posted in: #QUALiTYViVA, 8 Wastage, lean, MINTODEW, Muda, Quality  /  Comment: 0

mintodew in std In Japanese language “Waste” is “Muda” and muda is part of lean manufacturing, which is a method for eliminating the Muda (wastage). To implement the methodology for eliminating the Muda (wastage) in product manufacturing industry and / or in service industry one has to understand,
  1. What is Wastage (Muda)?
  2. What are types of wastage ?

Wastage:

To me, this can be put in a very simple and in lucid way as below: “In product manufacturing industry and / or in service industry step(s) or action(s) involve which are not required to complete that process, called as wastage”.

These wastage are categorized in 8 different types, they are,

  1. Motion
  2. Inventory
  3. Non-Utilization of talent
  4. Transportation
  5. Over production
  6. Defects
  7. Extra Processing
  8. Waiting
To make this simplified and understandable and to remember ,I am coining here with the acronym as MiNT “O” DEW and presented in model as below: Mint-O-Dew     Now, we will discuss each type of wastage and summarized them one by one:

  1. Motion:

This is considered as unnecessary movement of operational person to accomplish the given job. The examples are,
  1. Operational person’s movement for checking the requirement of quality norms in production, which can be made ready before start of production.
  2. Movement for taking print out in case of availability of centralized facility of printer, this may be point of debate that movement is waste or multiple printers are wastage and shall come to conclusion after proper study.
 

  1. Inventory:

Accumulation or piling up of any kind of product or WIP, involve the wastage of time and money. The examples are,
  1. Accumulation of invoice or purchase order and not delivered to parties concern.
  2. Accumulation of finished product and not dispatched on time.
 

  1. Non-Utilized talent:

The wastage happened when skill and knowledge of staff or worker are not utilized effectively to accomplish the job completely.  

  1. Transportation:

The waste in transportation result, when shifting between two processes/ operations center through complex route. The examples is,
  1. When operation process carried out at three different center say X , Y and Z in sequence, but center X and Z are at one place and Y is at distance , in such cases movement are from X to Y( at distance) and then Y to Z which involve excess transportation,  loss in handling cost and time to complete the job.
 

  1. Over production:

Manufacturing of product beyond the demand in the market is over production, result in loss in holding inventory, labor cost etc. The examples is,
  1. Printing of brochure more than required as planned, result in wastage of time, printing ink, paper etc.
 

  1. Defects:

Any product that is processed not as per the requirements of the customer’s need as agreed design document or technical condition, results in either scarp or involve repair or rework. This is wastage of time, money and manpower.

  1. Extra Processing:

Extra processing is nothing but, adding the unnecessary event i.e. an additional process or operation added in making / manufacturing a product ,the resultant is more or less than required, as per design or technical document. The examples is,
  1. If customer’s design having requirement for rough surface finish and this can be accomplished with no extra process, where as supplying material with mirror finish which results after adding extra process.
This extra processing is wastage of time, money, engagement of manpower and extra paper work.

  1. Waiting:

Unplanned stoppages results in waiting for process. Unplanned stoppages can be due to electrical, mechanical, operations, human related and unsafe condition. Also, due to deviation in quality of processed material, no availability or poor quality of raw material. Hope, acronym MiNT “O” DEW pronounces in rhythmic style will help to remember the 8 wastage and detailed analysis help to take action and minimizing them.