Lean manufacturing has defined seven causes of waste, all companies have experienced
one or more of the waste types described below.
Companies that fail to control such wastes are companies that sooner or later will
be out of business. Control of the “seven wastes” is a must for any organization
or company that is planing to succeed.
Overproduction causes consumption of raw materials that otherwise could be used on
actually demanded products, OP causes inadequate use of personnel, plus product and
material accumulation in the production floor that difficult the manufacturing process
Results in captive monetary resources that are not producing profit, increases tax
liability, make use of valuable storage space that can not be used for other purposes,
accumulated not sold inventories are at high risk of being damaged or rendered obsolete.
3-Unnecessary Transport of Materials or Equipment:
Facilities that do not permit good floor manufacturing layouts, process and other
factors can cause unnecessary transport of materials and equipment wasting labor
and energy resources
that do not add value to the product.
4-Inadequate or Obsolete Manufacturing Process:
Inadequate, necessary or obsolete manufacturing process causes low productivity and
defects prone operation, for example movement of people that do not add value to
5-Defects or bad Quality from Process or Design:
Poorly designed product or lack of good manufacturing instructions or training can
causes reworks, waste, bad quality products, customer low rating and products returns.
6-Waiting Time for Materials, Tools or Persons:
This lack of synchronization among all these production elements, during process
or sourcing causes delays on production and idle personnel and machinery.
7-Bad Process Design and Layouts:
Causes unnecessary actions or movement of people, tools, materials or equipment.