Muda Ad
Muda Ad
COLLAGE
3, Motion: This is not the motion of the product, but rather the
unnecessary movements of workers that are wasteful or harmful. This
may lead to strain injuries for workers, downtime, or equipment
breaking down due to wear and tear.
4, Waiting: A product not currently being processed or not in transport
is considered to be “in waiting.” When it sits waiting, the workflow is
interrupted and the value of the product decreases.
Defects in the end product: Improving processes with Kaizen will also
help to improve the quality of the product being made. When you are
able to improve your products, reduce the prices, and deliver them
faster, customers will be much more satisfied. Standardized work, a key
principle of Kaizen, also helps to ensure manufacturing is consistently
free of defects.
Kaizen Guide
The Toyota Production System, and later on the concept of Lean, was
developed around eliminating the three types of deviations that shows
inefficient allocation of resources. The three types are Muda ( waste),
Mura (unevenness), and Muri ( overburden).
Muda
There are seven categories of waste under Muda Type 2 that follow the
abbreviation TIMWOOD. The seven wastes are (1) Transport i.e. excess
movement of product, (2) Inventory i.e. stocks of goods and raw
materials, (3) Motion i.e. excess movement of machine or people, (4)
Waiting, (5) Overproduction, (6) Over-processing, and (7) Defects.
8 lean wastes
Mura
Muda, Mura, and Muri are interrelated. Eliminating one of them will
affect the other two. For example, a firm that needs to transport 6 tons
of materials to a customer has several options (Lean Enterprise
Institute, 2016).
The first option is to load one truck with all 6 tons and make a single
trip. However in this example, it would be considered Muri due to the
overburden of the truck. This excess load can lead to a breakdown.
The second option is to divide the transportation into two trips. One
with two tons and the other with four tons. This would be considered
Mura since the unevenness of the arrival of materials to the customer
can lead to problems at the receiving dock. In the first trip, the delivery
may be too little for the production necessary on-site. In the second
trip, the amount of delivered material may be too much for on-site
storage and material handling. This leads to Muri since one of the truck
is overburden and the receiver is also overburden for that delivery.
Additionally, Muda can be seen from the uneven workload. This can
cause employees who receive the materials to wait around.
The third option is to load two tons on each truck and make three trips.
Even though this option has no Mura and Muri, it has Muda since the
truck would not be fully loaded on each trip. Each truck can carry up to
3 tons of material and this option makes one unnecessary trip.
The fourth option is to deliver the materials with two trucks each with 3
tons. In this example, this would be the optimal level that minimizes
Muda, Mura, and Muri. Muda does not exist because the trucks are
carrying the loads at their maximum capacity. There is no excess
capacity nor unnecessary trips with this strategy. Mura does not exist
because the workload between the two deliveries are uniform. As a
result, there is no unevenness. And finally, Muri is absent from this
option because both the truck and the operators are not working
beyond their capacity.
teamwork,
personal discipline,
improved morale,
quality circles,
suggestions for improvement
• The process of changing from the current state to the future state –
The analytical and technical thinkers of our business need to
understand how we plan to get from Point A to Point B so they can
connect the dots in their mind’s perception of business as they know it
today.
• What role will I play in the change process? – Many members of your
organization are innovative and eager to contribute their insights and
suggestions for improvement. During the communication phase of our
project, we want to engage the “early adopters” to change. In change
management circles, this is usually no more than 20 percent of your
organization. These individuals are the free thinkers, the movers and
shakers, and typically the resources we know we can routinely call upon
to get things done. This is our first opportunity to recognize these
individuals in order to begin assembling the project team.
• How will the change affect me? – This is the age-old question, and
one of the most important messages required to gain the desire within
your organization to do something different. Fifty-two percent of
people engaged in the transformation effort prefer to have their direct
supervisor communicate how the changes will affect them. The changes
associated with the improvement process will affect people differently,
whether it is changes to day-to-day practices or, on a larger scale, a
complete change to their role and its responsibilities. At all levels of the
organization, the employee’s direct supervisor has the most influence
over what people hear and respond to. When communicating role
changes, changes to systems or tools that the employee uses day to
day, or even communicating changes to pay, benefits or time off, direct
supervisors are the most effective as a result of their relationship with
the individual.
It’s very important to be consistent. Craft your messages within the
plant or facility leadership team. One way that people will discredit the
improvement process or challenge leadership commitment is when
they receive mixed messages. Make sure you and your peers are
aligned, and don’t be afraid to use a script. It’s not so much the
presentation quality, but rather the content of the communication, that
is most important. People will recognize the position of the individual
within the organization (e.g. the senior manager or their direct
supervisor), and they will tune into the message being delivered, not
the method of delivery.
In another similar survey, 33% of the 360 firms from Spain and Mexico
adopted the Kaizen methodology, but they’re only a few traces of any
valuable improvements among them. In these studies, the biggest
obstacles to Kaizen implementation were the lack of concerted efforts
by the executives of the firms, poor implementation activities, lack of
resources, lack of a good return on investments for the continuous
improvement projects, staunch resistance to change by employees, as
well as resistance from Union members.
Among these, the lack of Kaizen software is usually the most common
and most challenging of them all. That’s when we get in, since we
facilitate the close tracking and monitoring of manufacturing
performances, in order to provide insights into the efficiencies of
operational activities and quality control.
Inconsistency in Efforts
Our company can help you ensure that the most common obstacles to
Kaizen implementation do not prevent you from enjoying
competitiveness in the 4th industrial revolution. We’re ready to offer
you our well-rounded expertise and our powerful solution to help you
to roll out continuous improvement processes in your organization.
Let go of assumptions.
Be proactive about solving problems.
Don’t accept the status quo.
Let go of perfectionism and take an attitude of iterative, adaptive
change.
Look for solutions as you find mistakes.
Create an environment in which everyone feels empowered to
contribute.
Don’t accept the obvious issue; instead, ask “why” five times to
get to the root cause.
Cull information and opinions from multiple people.
Use creativity to find low-cost, small improvements.
Never stop improving.
When you first try to do something different, whether it’s
changing a process, changing people’s mindsets or changing a
corporate culture, it is critical that you get your people onboard.
You need complete ownership and management team
participation to drive any of these improvements.
Kaizen for continuous improvement
Kaizen can be implemented in a condensed four steps, known as
PDCA / PDSA, the Shewhart cycle or Deming cycle. This iterative four-
stage approach, for continually improving processes, products or
services, involves systematically testing possible solutions, assessing the
results, and implementing the ones that are shown to work.
Importance of TPM
When everyone in a facility is thinking about and contributing
to maintenance, many aspects of the facility will change for the
better. Teams employing a TPM strategy often experience the
following:
Fewer breakdowns
When machine operators keep an eye out for changes with
their equipment, big issues are more likely to be spotted early,
before a breakdown occurs. This lets the maintenance team get
on top of their PM maintenance schedule, rather than always
reacting to emergency breakdowns.
Safer workplace
Technicians are much more likely to take risks when rushing to
fix a breakdown, so fewer breakdowns generally mean a safer
workplace. On top of that, when everyone keeps maintenance
in mind, problems can be spotted and dealt with well before
they become potentially dangerous situations.
Better overall performance
If everyone in a facility is keeping an eye on maintenance, small
fixes will stop going undetected, which helps you move away
from reactive maintenance and get backlog under control. It
takes the pressure of small jobs off the maintenance team so
they can concentrate on the bigger jobs, which increases the
overall performance of your facility.