lean management chapter 2

8/12/2019 Lean Management Chapter 2

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UnderstandingMUDA, MURA and MURI

Module - 2


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MUDAMuda means WASTE

Waste refers to any activity that does notadd value.

Waste only adds to time and cost.

Waste blocks flow


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Things to Remember about Waste:

Waste is really a symptom rather than a root causeof the problem

Waste points to problems within the system(At both process & value stream levels)

Elements of production that add time, effort, cost,

but no value

Waste


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MUDA Waste of Overproduction

Waste of Inventory

Waste of Repair / Rejects

Waste of Motion

Waste of Processing

Waste of Waiting

Waste of Transport


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Waste of Overproduction

Producing Moreor Sooner or Faster

than needed


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Waste of Inventory

Any Supply inexcess of onepiece flow


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Waste of InventoryBut most of all it hides all other problems

LongTransportation

Abse

nteeism

Communi

cationProblem

Long SetUp Time

Lack ofhousekeeping

LineImbalance

Quality

Problems

VendorDelivery

MachineBreakdown

PoorScheduling

Raw Material

Sea ofInventory

Finishedproduct tocustomer

Losses


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Waste of Repair / Reject

Inspection or repair of a

product or service to fulfillcustomer requirements


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Waste of Motion

Any movement that does notadd value


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Waste of Processing

Effort which adds no additional

customer value to a part


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Waste of Waiting

Being idle betweenoperations


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Waste of Transportation

Any movement of material that

is not required for Just-In-Time production


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MURAMura means IRREGULARITY

Whenever a smooth flow of work isinterrupted in an operators work, the flow of

parts and machines, or the productionschedule, there is mura


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MURAMura means IRREGULARITY

It can occur in:

Production Parts flow

Equipment usage

Work done by team members

Information flow

Material deliveries, causing shortage oroverstock


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MURA Benefits of eliminating Mura:

Shorter Lead times

Lower WIP

Faster response time

Lower cost

Greater production flexibility

Higher quality

Better customer service

Higher revenue Higher throughput

Increased profit !


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MURA

WaitTime

Overburden !!

Balanced

Team Member A Team Member B Team Member C

Cycle

Time

245

Cycle

Time

520

Cycle

Time

425

Takt Time430

Tim

e5

4

3

2

1


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MURIMuri means strenuous conditions for both workers andmachines as well as for the work process.

When machines are overburdened

We run the risk of causing safety hazards, equipment breakdownsand manufacturing defects.

When team members are overburdened:

The safety of the team members can be endangered

Workers are more likely to become exhausted or fatigued

It becomes difficult for team members to do each job with attentionto detail. This increases the frequency of defects, which in turnadversely affects the quality.


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MURIMuri means STRENUOUS WORK A profusely sweating operator

Squeaking sound from the machine

A newly hired worker assigned to do the job of aveteran without adequate training


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Muda, Mura and Muri in Office

Concepts


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1.Overproduction

Generating more information than the customersneeds right now

More information than the customer needs

More information than the next process needs Creating reports no one reads

Making extra copies


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2.Transportation

Movement of information that does not addvalue

Retrieving or storing files.

Carrying documents to and from sharedequipment.

Taking files to another person.

Going to get signatures.


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3.Motion

Movement of people that does not add value Searching for files

Extra clicks or key strokes

Clearing away files on the desk

Gathering information

Looking through manuals and catalogs

Handling paperwork


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4. Waiting

Idle time created when material, information,people or equipment is not ready. Waiting for:

Faxes

The system to come back up

Copy machine

Customer response

A handed off file to come back


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5. Processing

Efforts that create no value from thecustomers view point

Creating reports

Repeated manual entry of data

Use of outdated standard forms

Use of inappropriate software


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6. Inventory

More information, project material on hand than thecustomers needs right now

Files waiting to be worked on

Open projects

Office supplies

E-mails waiting to be read

Unused records in the database


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7. Defects

Work that contains errors, rework, mistakes orlacks something necessary

Data entry error

Pricing error

Missing information

Missed specifications Lost records


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Peoples Waste

Not using peoples (mental, creative, physical,

skill) abilities.Causes:

Management by fear and directive, politics

Poor hiring practices

Low or no investment in training

Low pay, high turn over strategy.

lean management chapter 2

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