7 Deadly Wastes Workshop

One of the biggest challenges and the biggest opportunity in Continuous Improvement is learning to see waste in all it's forms. It is easy to see some waste but many of the wastes identified by the Toyota Production System are harder to recognise and in some cases seen as a good thing in traditional manufacturing. Flyer

In traditional manufacturing long runs are encouraged and finished goods in warehouses are classed as being assets to the business. Lean Manufacturing is focused on reducing the time between paying for raw materials and other inputs into the production process and getting paid.

What are the 7 Deadly Wastes?

Waste is anything that adds cost not value to a product.

• Overproduction

• Wait time

• Transportation

• Processing methods

• Inventory

• Motion

• Defects

Continuous Improvement is a process of reviewing the process looking for waste and opportunities to cut it out of the process. In many cases the time that actual value is being added to the product is very small as low as 2% of the total time line. From a lean perspective the other 98% is waste.

At it's core lean manufacturing is simply the ongoing, systematic process of identifying and eliminating waste from the production system and associated support services.

Often organisations begin the process of eliminating waste and based on calculations of how much time is wasted in a process they undertake projects and activities to redesign the process and reduce the time that step of the process takes to perform. But unless the constraints within the system are worked on you're unlikely to see any significant improvement to the bottom line. Benefits flow from eliminating waste in the constraint points of the process - if the constraints are not identified and worked on all you achieve is increased capacity - where you can't use it.

The 7 Deadly Wastes Workshop is an interactive workshop designed to develop the ability to 'see' waste in all it's forms in your own production system, to understand the Theory of Constraints and how it applies to your business and to begin to develop a plan to eliminate waste at your constraint points.

Who should attend?

The Workshop suits groups from a variety of areas within your business.

• Senior leaders and the management team

• Work crews and their leaders

• A people from across the business - head office, supply chain, manufacturing, reliability and stores focusing in on a specific value stream.

Having a development day or shut down?

This is an excellent site wide activity suitable for a development days or shut downs or to integrate into other on-site training

Program outcomes

The workshop provides the opportunity for participants to learn to identify waste in thier area of responsibility. We can incorporate training about 5S workplace organisation if you are at the begining of your lean journey or focus on taking your implementation to the next level if you have the basics in place.

By the end of the workshop the participants will understand how all 7 forms of waste identified by Toyota present themselves in your business and have developed an action plan for the reduction in waste aligned to your key drivers for improvement.

Overview of the Workshop

• Paticipants will view a screening of Bruce Hamiltons Toast Kaizen and participate in a discussion identifing some of the examples of each type of waste in your production system. The Toast Kaizen Video takes the concepts of waste out of an industrial setting to help participants to deepen their understanding of the various types of waste.

• The next step is to go out to the various work areas and identify specific examples of waste in the participants own work areas.

• This input is then brought back to the training room and the participants workshop putting in place improvement plans aligned to the site objectives.

For more information contact us on 03 9697 1106 or via email