Answer to Question #306469 in Management for Marencia

Question

Identify and briefly discuss the effects of the 7 waste of lean manufacturing as you experience them in your workplace. Include relevant workplace examples to support your discussion.

1. Waiting (5)

2. Transporting (5)

3. Processing (5)

4. Inventory (5)

5. Motion (5)

6. Defects (5)

7. Overproduction (5)

Answer 1

i) Waiting is the wasted time due to halted or slowed production, which results in wasted labor, energy, and wages of the employees when there is no production. A good example a good product taking longer in the production line making the transport drivers to have more free time while they are being paid regardless of whether they work or not. This leads to a general loss in terms of profits.

ii)Transporting adds no value to a product despite the use of resources in handling the products or goods. Transportation cause the waste of waiting because part of a production chain must wait for a material to arrive. Transportation can cause damages to the product en route causing production of low quality goods.

iii) Processing refers to any additional component in manufacturing that is unnecessary. The effects include wastage of labor, raw material, and parts used in production. A good example include painting of car parts that cannot be seen by the customer or unnecessary plastic packaging on fresh fruits and vegetables.

iv) Excess inventory leads to deterioration of work-in-progress and wastes of packaging materials. A good example of inventory waste in storing of too much sugarcane, which cannot be processed leaving them to dry up in the warehouse and thrown away after resources such as light and space has been used.

v)Motion leads to consistent replacement of the worn out machines. Moreover, motion leads to deterioration of the health of employees if they do not wear any protective gears on places where motion occurs like the legs, or knees.

vi) Defects are the products produced that do not meet customer requirements. Defects leads to loss of customers if they are given the defects or leads to loss of resources including manpower, space, production parts, and even light. Producing for example cooking oil that does not meet the standards of the customer will make the company to dispose the product, making them to go at a loss.

viii) Overproduction leads to production of more products that is actually needed. It leads to excessive capital being tied up and storage costs, which become obsolete since the products will not be purchased. It leads to pollution of the environment, especially if the products are hazardous for example if they contain plastics.