Superfluous movement of materials
Although resources are needed to transport materials, no value is added. What’s more, material damage can be incurred during transportation.
Solution: Work stations are positioned in closer proximity to one another and work steps are synchronized and interlinked if possible.
High stock levels in the warehouse
An overfilled warehouse is a sign of both sub-optimal planning and a lack of understanding about the quantities of materials needed.
Solution: Processes are stabilized and, above all, standardized
If ergonomic principles are not observed during work bench design in production, meaning staff end up having to work in awkward positions, this has a negative impact in two ways – employees’ health suffers and it takes them much longer to complete their tasks.
Solution: Assimilating ergonomic principles and using an ergonomic Work Bench System.
Avoidable Waiting Times
Even though waiting times can’t be eliminated entirely, they should be prevented wherever possible, since no value can be added during these periods.
Solution: Staff are deployed to full capacity (by ensuring they can cover various different stations, for example) and take on additional tasks.
Capital is tied up for too long because demand has been incorrectly assessed. Over time, product materials may also deteriorate while they are in the warehouse.
Solution: The pull principle is established – in other words, the process chain is synchronized with the customer takt time.
Overly complex processes/overengineering
Waste is also produced by processes that are outdated or unnecessarily complex. A design that far exceeds the functionality of a product doesn’t add value either.
Solution: Focus on continuous improvement and scrutinize company processes
Rejects and Reworking
When production errors occur, the results of the work are either completely unusable or else need to be re-engineered.
Solution: Use of measures to increase product quality, e.g. by optimizing the work bench via the 5s method and preventing errors through application of the Poka-Yoke principle.