It shows up in additional signature approvals, data entry or data format changes, frequently revising documents or information, or complex forms or databases that require information to be entered repeatedly. Your email address will not be published. Examples. Although it could be possible to complete one product in 5 minutes from start to finish, this batch of 100 will take over a week to get through the wasteful production system. • Over-processing • Motion • Inventory • Waiting • Defects • Overproduction. https://joeelylean.blogspot.com/2005/11/overprocessing-waste-example.html , the one I’ve always had the hardest time explaining is “Overprocessing,” sometimes called “inappropriate processing.” It always seems to glass people over. Simply knowing what the catagories are, however, is not enough – understanding some common examples and how each waste can be interpreted can benefit you in better understanding the efficiency your organizations processes.

I’m convinced, though, that the biggest waste from overprocessing comes a far different type of equipment. Over production appears when processes are not efficient. Watch Velaction Videos | Visit Our Continuous Improvement Store, Last updated by Jeff Hajek on May 30, 2019. To prevent overprocessing waste, implement standardized processes during 5S. Anyone who has been around Lean for more than a day or so has dived into the seven wastes (eight with unused creativity thrown in). 2.

Equipment that takes just a little too much. The seven wastes have been used successfully to improve both transactional and manufacturing processes. Eliminating Manufacturing Waste: Transportation, Motion, Waiting and Over-Processing. •  Extra packaging that is not needed. If you have any questions, please contact us at one of the methods below: FREE CONSULTATION:  https://calendly.com/jwholbus. That’s the waste of over processing. Author: Andy Welna Lean manufacturers around the country are tackling waste, becoming more efficient and lowering production costs every day. → Complex purchasing processes with multiple approval levels. Over production. I’d love to hear more.

The most common explanation given about overprocessing is that it is the act of doing extra, non-value added steps. Over-production. In the case of a plastic part, spending time trimming material in areas of the part that will not be seen in the vehicle is a waste (considering the part still … Examples of liquid waste include wash water from homes, liquids used for cleaning in industries and waste detergents.

But there is far less commonly discussed nuance to overprocessing waste. They build ergonomically correct workstations, add shock absorbing mats to work areas, use tool balancers, and implement a whole bunch of other techniques to keep tired muscles from affecting production. The linkage is weak. The content on this page is part of Phase 4, “Building the Foundation”, of our Continuous Improvement Development System.

No personal data is stored, CASE STUDY: How General Electric Used Six Sigma to Transform Their Company, Lean Six Sigma Black Belt Certification Requirements - IASSC Body of Knowledge, Lean Six Sigma Green Belt Certification Requirements - IASSC Body of Knowledge, Lean Six Sigma Yellow Belt Certification Requirements - IASSC Body of Knowledge, SIX SIGMA ONLINE CERTIFICATION – WHAT IT'S ALL ABOUT AND WHY YOU NEED IT, WHY SIX SIGMA BLACK BELTS MAKE BETTER LEADERS (Part 1). P: Over Processing, which results from inefficient processes that use more steps or tools than are actually required for the desired outcome.

Overprocessing leads to additional labor costs and material costs. A good worker will go above and beyond if there are not clear instructions on what needs to be completed in a task. Let’s talk a little about the waste of overprocessing. Solid type: Solid waste predominantly, is any garbage, refuse or rubbish that we make in our homes and other places. This article attempts to link over-processing to mental fatigue. Are you saying that the article is weak at showing that having to perform overprocessing tasks (i.e. A journey to respect people and eliminate waste. 7. Create standard operating procedures (SOP) for each work station and provide them to each employee and at the workstations. One example of defect waste is the time spent looking for an item missing from a surgical case cart.

People tend to work slower and make more mistakes at the end of a long day than they do at the start of a shift. Reworking the defects is time consuming and it has to be performed for all 100 pieces. Processing too soon or too much than required • Information sent automatically even when not required • Printing documents before they are required • Processing items before they are required by the next person in the process. I am talking more about the small incremental slowdown of equipment that saps productivity. For example, printing out an e-mail for filing, or grinding a burr off a product after a cutting process. During the initial design, tasks may be included into the process that are thought to add value but once the process is live you find out that they do not. Get exclusive deals you will not find anywhere else straight to your inbox! The causes of overprocessing are not having standardized instructions or requirements, or over-designing the process to add additional tasks or activities that do not add value.

Watch the phase overview video here, or click the banner below the video to see all the content in our Phase 4 Video Series. While it is easier to understand why excess motion or transportation is a waste, this overprocessing waste seems to many to simply be giving the customer a little extra. A computer filled with too much electronic baggage, making programs sluggish. •  Thirty pages of instructions when you only need two pages → Another example: X-ray is sufficient and we go for an MRI. It is an extra step that adds cost but not value. The operator gets to work fixing the problems. Rotating jobs to keep employees fresh, focusing on morale as a Lean strategy, and developing effective employee-boss relationships all contribute to reducing the waste of intellectual overprocessing. This website uses cookies in order to work correctly. These include old car tires, old newspapers, broken furniture and even food waste. Your email address will not be published. Most employers pay attention to physical stressors. The waste of overprocessing is caused when tasks, activities, or material is added to a product that does not meet the end customer’s requirements. •  Painting areas of a product that will never be seen

Over-processing. For example, in the automotive industry, many parts are visible in the car, however the entire part may not be visible. If Changeovers are too slow, one would over produce; if quality if poor, again, one would over produce, just in case. Tired, chronically tense employees are slower, and less effective than well-rested, happy, satisfied employees. Managing the intellectual slowdown is far less common. One of the wastes is the waste of overprocessing. Employees or machines are taking additional time to add extra paint or packaging that is not required. It comes from fatigued and stressed gray matter. This time could be spent on other activities. Required fields are marked *, (C) 2020 Velaction Continuous Improvement, LLC. Having a SOP across workstations and shifts will improve quality and reduce overprocessing waste.

It chronicles my efforts to implement the Toyota Production System in now two different orginizational settings.

I’m always up for a good debate, and always want to make my content better. emailing and then faxing a document, or watching the hourglass on your screen, or staring at a drill bit for an extra 30 seconds) is fatiguing, or are you saying that you don’t believe that those sorts of tasks are fatiguing? What are you doing to keep you, or your team, from spending more brainpower on a job than you need to? The most common explanation given about overprocessing is that it is the act of doing extra, non-value added steps. Waste of Over-production. Over Processing_Waste Examples: → If Microsoft Excel is enough for us and we go for mini-tab for calculation. Excess processing often results from the creation of multiple versions of a piece of work that now must be reconciled into the true work. ... for example. For example, printing out an e-mail for filing, or grinding a burr off a product after a cutting process. The worst of the 7 wastes – as it incorporates all the other wastes as well. Every piece of material spent is material that cannot be used on other products. Waste of Defects.

One of the wastes is the waste of overprocessing. But there is far less commonly discussed nuance to overprocessing waste. The waste of overprocessing is caused when tasks, activities, or material is added to a product that does not meet the end customer’s requirements. I started writing Learning About Lean in September 2002. → If the lathe machine is sufficient for operation and we are doing the operation with the CNC machine. A drill bit that is a little too dull, costing a few extra seconds per hole.