LO2: Identify MUDA and problem
Information Sheet-1 Preparing and implement Plan of
MUDA identification
2.1. Targets of Customer
Customer is the one who buys products/services from
manufacturers/service providers. So the customer does
not bother how the manufacturer/service provider makes
it. Now a days customers have many alternative
manufacturers/service providers to buy the same type of
product/service from and choose one that fulfills their
targets which are listed below:-
Customer needs better quality
On time delivery
Reasonable price
2.2. Targets of Manufacturer/Service provider
The primary target of Manufacturers/Service
providers is to earn profit. So as to meet his/her
target, he/she needs to satisfy the targets of
customers in such a way by providing better quality
product/service on time and at a reasonable price. If
he/she is able to do so, he can win customers‟
targets. Then to get higher profit the
Manufacturer/Service provider needs to minimize
his/her costs by reducing/eliminating wastes and
following effective working procedures.
2.3. The concept of Cost
Cost :- is the amount of money that is
expended to accomplish a given
task/operation.
Cost can be of Manufacturing or Service
Delivering cost=(material + labor + facility
+ utility + others)cost
Determination of the sales price of the
product/Service Sales price=(manufacturing
or service delivery)cost + profit
2.4. Traditional Thinking of Price Setting
In traditional thinking of price
setting, price is determined by the
manufacturer/service provider
rather than the market itself.
When there is shortage of supply
then the manufacturer raises selling
price.
2.5. Kaizen Thinking of Price Setting
In modern time, there are a large number of
manufacturers/service providers delivering the same type of
product/service offering the customers a great deal of options
to buy products/ services. Price is determined by the
interaction between market demand and supply.
Manufacturers/service providers ,who want to set selling price
above the market price, customers will not be willing to buy
their products/services. Manufacturers/Service providers to be
competent in the market they should provide Quality
product/service on time and at the market price. Since to days
economy is market based, we should focus on minimizing our
costs and not maximizing selling price to maximize our profit.
2.6. Waste/Muda
Waste/Muda is any activity which
consumes resources, such as money,
time ,energy, materials, etc, that does not
create value and can be eliminated.
Value
Value is defined by the next customer
(Know your Customers Need).
The next process is your customer. The
activity/effect exactly what the next
customer needs is value adding activity.
There are two types of customers:-
Internal customer
External customer
Internal customer:- is the customer
within a production line/service
delivering sequence that is next to the
previous process and makes his/her own
process.
External customer:- is the customer
that buys the final out put
product/service of the enterprise.
2.7. The three Categories of Operation
1. Net Operation/Value Adding Operation
2. Non-Value Adding Operation
3. ”Muda‟‟
1. Net Operation/Value Adding Operation
Part of an operation that adds value to make parts and
products or deliver service. In other words, it is part of the
operation that the customer exactly needs / willing to pay for.
Examples - Milling, Turning, Grinding, Assembling and
Welding.
- Printing/photocopying a document etc.
2. Non-Value Adding Operation
Part of operation that adds no value
but cannot be avoided rather it can be
reduced.
Example Setting up / adjustments,
Loading paper to a photo copy
machine/printer etc
3)”Muda’’
Muda is a Japanese word meaning Wasteful Activity
which use resources, time or cost without adding value.
In other words, it is anything unnecessary in operation that
affects the quality of the product/service, productivity,
delivery time and also production cost. Muda can be
eliminated immediately.
Example:- Unnecessary motion/searching for tools,
unnecessary transportation of materials, over production,
Inventory, Waiting /idle time, making defects and over
processing etc.
Information Sheet-2 Causes and effects of MUDA
2.1. Causes of Muda of Overproduction
Large-lot production
Anticipatory production (producing product
in advance of demand)
Inability to achieve short changeover times
with the large equipment used in mass
production systems
Creating enough stock to replace the number
of defective parts produced
Overstaffing or too much equipment
Machines that turn out parts too quickly
2.2. Effects of Muda of Overproduction
Companies often have overproduction as a
result of large-lot manufacturing methods or
mass production. there are several
unfortunate effects of over production:
Anticipatory buying of parts and materials
Blocked flow of goods
Increased inventory
No flexibility in planning
Occurrence of defects
2.3. Causes of Muda of Inventory
Acceptance of inventory as
normal or as a “necessary evil”
Poor equipment lay out
Long changeover times
Shish-kabob or large lot
production
Obstructed flow of goods
Anticipatory production
2.4. Effects of Muda of Inventory
Waste of space
Needs for inspection, and
transportation
Expansion of working fund
Shelf life may expire
It ties up cash
Makes FIFO inventory
management more difficult
2.5. Causes of Muda of motion
Isolatedoperations
Low employee morale
Poor work layout
Lack of training
Undeveloped skill
2.6. Effects of Muda of motion
Increase in manpower and processing
Unstable operation
Increases production time
Can cause injury
2.7. Causes of Muda of
Conveyance/Transportation
Poor layout
Shish-skilled workers
Sitting to perform operations
The need for conveyance systems is
assumed
2.8. Effects of Muda of Conveyance/Transportation
Waste of space production deterioration
Expansion of transportation
facilities
Occurrence of scratches
Increase production time and cost
wastes time and energy
2.9. Causes of Muda of Waiting/ Idle time
Obstruction of flow
Poor equipment layout
Trouble at the upstream process
Capacity imbalances
Large Lot-production
2.9. Causes of Muda of Waiting/ Idle time
Obstruction of flow
Poor equipment layout
Trouble at the upstream process
Capacity imbalances
Large Lot-production
2.10. Effects of Muda of Waiting/ Idle time
Waste of manpower, time, & machines
Increase in the in-process inventory
Failed delivery dates
Poor workflow continuity
2.11. Causes of Muda of Defect making
Emphasis on downstream inspection
No standard for inspection work
Omission of standard operations
Material handling and conveyance
2.12. Effects of Muda of Defect making
Increase in material cost
Productivity deterioration
Increase in personnel & processes for inspection
Increase in defects and claims
Invite reworking costs
Inadequate study of operations
2.13. Causes of Muda of Processing
Incomplete standardization
Materials are not studied
2.14. Effects of Muda of Processing
Unnecessary processes or operation
Increase in manpower and man-hour
Lower workability
Increase in defects
Can reduce life of components
Information Sheet-3 Using of Tools and techniques to
draw and analyze current situation of the work place
3.1. Classification of Waste
A number of methods for
categorizing types of waste have
emerged. We will review some of
these models to get a deeper
understanding of what waste is and
how to find it and eliminate it.
The three Mus
The 5M + Q + S
The flow of goods
The seven deadly wastes
The Three MUs
In Japanese this is expressed with
the terms muda,mura and muri.
Muda(waste) = Capacity
exceeds load.
Mura (inconsistency or
variation) = capacity sometimes
exceeds the load and the load
sometimes exceeds capacity.
Muri(irrationality/physical or
mental overburden) = load exceeds
capacity.
The 5M + Q + S
Another way of thinking about
waste is to focus on the areas where
waste may occur: the 5M (man,
material, machine, method and
management), plus quality and
safety. See the next figure.
The Flow of Goods
Materials are procured:- Materials are retained in
the warehouse Materials are conveyed to processes
on the production line Materials are retained at the
process equipment(WIP) Materials are picked up
for processing Materials are processed:- goods are
set down and retained on the other side of the
processing machine(WIP) Goods are conveyed to an
inspection point
Goods are retained until inspection Goods are
picked up and inspected Goods are set down and
retained on the other side of inspection process
Inspected goods are conveyed to the finished goods
warehouse Finished goods are retained prior to
shipment Finished goods are delivered to the
customer.
The Seven Deadly Wastes
Identifying and eliminating these
seven types of waste will forge the
path to lean production.
Overproduction
Inventory
Motion
Conveyance/Transportation
Waiting/ Idle time
Defect making
Processing
Motion
These are non-value adding
movements or more than
necessary movements of workers,
equipment, and machines, such
as looking for goods, bending,
stretching, walking, lifting,
reaching etc.
Conveyance/Transportation
It is Unnecessary transportation of
parts between processes caused by
unnecessary transportation distance,
temporary storage, relocations or re-
piling up. Transportation does not create
any value added except for
transportation companies.
Transportation is usually difficult to be
totally eliminated but reducing is
possible.
Waiting/ Idle time
Refers to both human and machine
waiting.
This includes all kinds of waste of
time such as workers or parts waiting:
-for an upstream process to deliver.
-for a machine to finish processing.
-for incoming parts or materials.
-for process that has a long wait
time.
Defect making:- This includes
defects, inspections for defects in-
process, and claims, rescheduling,
and resource loss.
Processing:- This consists of
processing and operations
primarily unnecessary. It is
processing beyond the standard
required by the customer.
Information Sheet-4 Identifying and measure Wastes/MUDA
3.1 Some of the benefits of identifying and
eliminating waste To the company
Benefits to the company include:
1. Cutting the hidden costs of production-
It is estimated that 80 percent of production
activities and associated costs are non-value-
added, or waste. When factories begin to
focus on identifying and eliminating waste,
the impact on the bottom line is
astronomical.
2. Increased customer satisfaction-
Customer satisfaction rises as a direct
result of implementing lean
production. When waste is eliminated
from production, deliveries occur on
time and product quality goes up.
Benefits to individuals include:
1. Increased job satisfaction- No longer
will you spend hours looking for missing
tools, waiting for materials to arrive,
walking around piles of inventory, lifting
and setting
down heavy parts or tools, working in
unsafe conditions and all the other things
you have to do that are not essential to
your job.
Plan and procedure for Waste/Muda Identification
The steps to effective waste
identification are:
1. Make waste visible
2. Be conscious of the waste
3. Be accountable for the
waste.
4. Measure the waste.
1. Make waste visible
Waste can be made visible
in several ways such as:
Shop layout analysis
Process flow analysis
Take photos/video
Etc
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