The 8 Wastes
THE BASICS OF 2-SECOND LEAN
Waste comes in many different types, it’s a way that we identify flaws or problems with processes. Each waste can be solved or reduced in many different ways. There are 8 main wastes identified within 2-Second Lean, we will talk about each one, and give an example to help you visualise it.
The key aim of 2-Second Lean is to reduce and eliminate waste. This means that understanding what is waste and how it is caused is absolutely vital to becoming a Lean Thinker.
Almost all the problems and flaws you will see in a business can be put into one of those 8 wastes. Understanding each waste will help you to identify it in your own work. Once you have identified them, you can start to make improvements to reduce or remove them.
It is worth understanding that one waste can also lead to another waste. For example, Waiting is a waste commonly caused by Over-Production, Over-Processing or Defects. A worker can be left waiting for the part they need because there are too many being made and the production time is longer. They could be waiting because a previous process is too long and involves too many steps which involve delays. They can be left waiting because the parts arrived to them defected, and now those same parts must be re-worked, leading once again to over-processing.
We’ll look in more detail at wastes causing other wastes in “The 5 Why’s” in a later chapter.
1. Over Production
This is where you are making more of a part or and item than you actually need.
Example: You need 10 of a particular toy but end up producing 20. Think of all the extra time and effort that has been spent making those extra items.
2. Transport
This is where there is extra time and effort being used to move products or materials.
Example: You are having to move some toys from production to your warehouse which is a 200m walk. Why not place them in a location that is closer?
3. Excess Inventory
This is where you have produced or bought more than you need. Often caused by the first waste, Over-Production.
Example: You buy 3000 of a particular type of wheel for toy cars. You may get a better price, but storing that could be a problem. If the item isn’t used, it could get damaged or defected.
4. Defects
This is where something you have made or done has had errors in it and needs fixing or re-working to correct it.
Example: You are producing a toy car and the wheels come to you with chips in the paintwork, you have a defect. Fixing this by re-making the part and repairing the product is more time and effort than should have been spent on it.
5. Excess Motion
This is where you have unnecessary movements or actions involved in a process.
Example: You are walking 10ft to get a screwdriver each time you need it. Why not just move it closer to you so you don’t have to leave your workbench?
6. Over-Processing
This is where you are adding more steps or more work than is required. The over-processing of something can often be caused by the fourth waste, Defects.
Example: You are adding some stickers to a product, 3 on the front and 2 on the back. Does it need that many stickers or could you put two bigger stickers and save the extra time and effort?
7. Waiting
This is where you have to wait for something before you can continue working.
Example: You are making a toy car but the wheels you need to complete them haven’t arrived yet. Think of how much time is wasted on people waiting for things they need?
8. Unused Employee Genius
This is when you aren’t utilising the skills and talents of your employees effectively. Make sure people are doing the jobs they are most suitable for and listen to what they have to say. This is often caused by reworking defects, over-processing on poorly implemented systems, or waiting to continue work.
Example: You have talented employees who have a wealth of knowledge that could fix some of your issues. If you are not tapping into that knowledge to improve your company, that is a waste of their skill.
9. Communication (UNOFFICIAL)
There is often considered to be 9th, unofficial, waste. That is communication. Communication can be the key reason for many of the above wastes and it often the root cause of problems and issues that a company faces. Whether it be verbal, written or online communication, bad information, ambiguous information can cause waste or defects.
Exercise
Look at the daily improvements that have been made in your company. Can you identify which waste has been reduced or eliminated with each improvement? Ask your employees to start identifying which waste they have eliminated with their improvements to further their understanding.
